Blade grinding systems and methods

Abstract

A method of grinding a plurality of tufting blades of a blade assembly is disclosed. The plurality of tufting blades can be received within a blade block during grinding. The blade assembly can have a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes. Each tufting blade of the plurality of tufting blades can have a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis. The plurality of tufting blades can be spaced from each other along the third axis. The blade block can include at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block.

What is claimed is: 
     
         1 . A method comprising:
 grinding a plurality of tufting blades of a blade assembly, wherein the plurality of tufting blades are received within a blade block during said grinding,   wherein the blade assembly has a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes, wherein each tufting blade of the plurality of tufting blades has a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis,   wherein the plurality of tufting blades are spaced from each other along the third axis, and   wherein the blade assembly comprises at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block.   
     
     
         2 . The method of  claim 1 , further comprising:
 with the at least one fastener in a disengaged condition that permits movement of the plurality of tufting blades relative to the blade block, positioning, using a first guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a grinding configuration; and   securing, using the at least one fastener, the plurality of tufting blades relative to the blade block in the grinding configuration.   
     
     
         3 . The method of  claim 2 , wherein positioning, using the first guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis comprises:
 moving, by a first linear actuator, the plurality of tufting blades along the first axis in a first direction; and   moving, by the first guide and a second linear actuator that is coupled to the first guide, the plurality of tufting blades along the first axis in a second direction that is opposite the first direction.   
     
     
         4 . The method of  claim 1 , wherein grinding the plurality of tufting blades comprises passing a grinding wheel across the tufting blades along a grinding axis that is within 20 degrees of parallel to the second axis. 
     
     
         5 . The method of  claim 1 , further comprising: positioning the blade assembly within a fixture that is configured to hold the blade assembly during grinding. 
     
     
         6 . The method of  claim 1 , further comprising:
 after grinding the plurality of tufting blades of the blade assembly, with the at least one fastener in a disengaged condition that permits movement of the plurality of tufting blades relative to the blade block, positioning, using a second guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a tufting configuration; and   securing, using the at least one fastener, the plurality of tufting blades relative to the blade block in the tufting configuration.   
     
     
         7 . The method of  claim 1 , further comprising receiving a plurality of blade assemblies positioned within a carrying tray. 
     
     
         8 . The method of  claim 7 , wherein receiving the plurality of blade assemblies positioned within the carrying tray comprises receiving the carrying tray on a first conveyor. 
     
     
         9 . The method of  claim 8 , further comprising moving, by the first conveyor, the carrying tray to a first end of arm tool. 
     
     
         10 . The method of  claim 9 , further comprising: moving, by the first end of arm tool, a first blade assembly of the plurality of blade assemblies received by the carrying tray to a second conveyor. 
     
     
         11 . The method of  claim 10 , further comprising: visually inspecting each tufting blade of the first blade assembly prior to grinding. 
     
     
         12 . The method of  claim 11 , further comprising replacing at least one tufting blade of the blade assembly that fails inspection with a replacement tufting blade from a replacement tufting blade supply. 
     
     
         13 . The method of  claim 5 , further comprising: positioning, by a second end of arm tool, the blade assembly on the fixture. 
     
     
         14 . A system comprising:
 a blade assembly comprising a plurality of tufting blades received within a blade block, wherein the blade assembly has a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes, wherein each tufting blade of the plurality of tufting blades has a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis, wherein the plurality of tufting blades are spaced from each other along the third axis, wherein the blade assembly comprises at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block;   a fixture that is configured to hold the blade assembly; and   a grinder that is configured to grind the tufting blades of the blade assembly held within the fixture.   
     
     
         15 . The system of  claim 14 , further comprising:
 a first blade alignment assembly that is configured to position each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a grinding configuration.   
     
     
         16 . The system of  claim 15 , wherein the first blade alignment assembly comprises a first linear actuator that is configured to move the plurality of tufting blades along the first axis in a first direction; and a second linear actuator coupled to a first guide, wherein the second linear actuator is configure to move the plurality of tufting blades with the first guide along the first axis in a second direction that is opposite the first direction. 
     
     
         17 . The system of  claim 15 , further comprising:
 a second blade alignment assembly that is configured to position each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a tufting configuration.   
     
     
         18 . The system of  claim 17 , wherein the second blade alignment assembly comprises a first linear actuator that is configured to move the plurality of tufting blades along the first axis in the first direction; and a second linear actuator coupled to a second guide, wherein the second linear actuator is configure to move the plurality of tufting blades with the first guide along the first axis in the second direction. 
     
     
         19 . The system of  claim 14 , further comprising:
 a first conveyor that is configured to receive a plurality of blade assemblies in a carrying tray; and   a first end of arm tool that is configured to transfer each blade assembly of the plurality of blade assemblies from the carrying tray to a second conveyor.   
     
     
         20 . The system of  claim 19 , further comprising a second end of arm tool that is configured to:
 transfer the blade assembly from the second conveyor to the fixture for grinding; and   transfer the blade assembly from the fixture to the second conveyor after grinding.   
     
     
         21 . The system of  claim 14 , further comprising a visual inspection assembly that is configured to inspect each tufting blade of the blade assembly. 
     
     
         22 . The system of  claim 21 , wherein the visual inspection assembly is configured to determine whether the blade assembly passes or fails at least one visual inspection metric.