Continuous cutting horizontal multi-wire stone cutting machine

1 . A material cutting system for cutting a unit of input material, the material cutting system comprising:

a frame;

a plurality of rollers rotatably supported on the frame; and

a cutting assembly including:

a plurality of pulleys rotatable relative to the frame about a vertically extending axis;

a drive motor drivably connected to the plurality of pulleys; and

a plurality of cutting wires entrained on the plurality of pulleys such that rotation of the pulleys via the drive motor cycles the cutting wires horizontally,

wherein the plurality of rollers are configured to rotate thereby advancing the input material unit toward the cutting wires such that the plurality of cutting wires cut a plurality of vertically spaced kerfs into the input material unit and hence form a plurality of cut sections, and

wherein the plurality of cutting wires are configured to pass through the plurality of kerfs in a first direction in a cutting phase and in a second direction opposite the first direction in a return phase thereby effecting continuous cutting of the unit of input material.

2 . The material cutting system of claim 1 , wherein the plurality of pulleys and hence the plurality of cutting wires are configured to be vertically adjustably spaced from each other for cutting the input material unit into the plurality of cut sections of predetermined thicknesses.

3 . The material cutting system of claim 2 , wherein the cutting assembly further includes a drive train having a drive shaft configured to removably receive some of the plurality of pulleys.

4 . The material cutting system of claim 1 , wherein the cutting assembly further includes a plurality of straight mounting arms and a plurality of offset mounting arms, some of the plurality of pulleys being mounted on the plurality of straight mounting arms and some of the plurality of pulleys being mounted on the plurality of offset mounting arms.

5 . The material cutting system of claim 1 , further comprising a plurality of drive motors configured to rotate some of the plurality of rollers, and a control system configured to independently activate the plurality of drive motors for selectively advancing the input material unit and another input material unit.

6 . The material cutting system of claim 1 , further comprising a shimming system configured to automatically insert shims into the kerfs.

7 . The material cutting system of claim 6 , further comprising a control system configured to control the shimming system such that shims are insertable at adjustable heights.

8 . The material cutting system of claim 6 , further comprising a control system configured to control the shimming system such that shims are insertable at a plurality of heights within a single cutting operation.

9 . The material cutting system of claim 1 , wherein some of the plurality of rollers are configured to be adjusted vertically for accommodating input material units of different sizes.

10 . A stone cutting system for cutting a stone block, the stone cutting system comprising:

a cutting station including:

a frame;

a lower conveyor including a first plurality of rollers and supported on the frame;

a middle conveyor including a second plurality of rollers, the middle conveyor being vertically adjustable on the frame;

an upper conveyor including a third plurality of rollers;

at least one drive motor drivably connected to at least one of the first plurality of rollers, the second plurality of rollers, and the third plurality of rollers for advancing the stone block on one of the lower conveyor, the middle conveyor, and the upper conveyor; and

a cutting assembly including:

a plurality of pulleys rotatable relative to the frame about a vertically extending axis;

a drive motor drivably connected to the plurality of pulleys; and

a plurality of cutting wires entrained on the plurality of pulleys such that rotation of the pulleys via the drive motor cycles the cutting wires horizontally,

wherein at least one of the first plurality of rollers, the second plurality of rollers, and the third plurality of rollers are configured to rotate thereby advancing the stone block toward the cutting wires such that the plurality of cutting wires cut a plurality of vertically spaced kerfs into the stone block and hence form a plurality of stone sections.

11 . The stone cutting system of claim 10 , further comprising a loading lift including a carriage configured to raise the stone block to the middle conveyor or the upper conveyor.

12 . The stone cutting system of claim 10 , further comprising an unloading lift including a carriage configured to lower the stone block from the middle conveyor or the upper conveyor.

13 . The stone cutting system of claim 10 , wherein the plurality of pulleys and hence the plurality of cutting wires are configured to be vertically adjustably spaced from each other for cutting the stone block into stone sections of predetermined thicknesses.

14 . The stone cutting system of claim 10 , wherein the cutting assembly further includes a plurality of straight mounting arms and a plurality of offset mounting arms, some of the plurality of pulleys being mounted on the plurality of straight mounting arms and some of the plurality of pulleys being mounted on the plurality of offset mounting arms.

15 . The stone cutting system of claim 10 , further comprising a shimming system configured to automatically insert shims into the kerfs.

16 . The stone cutting system of claim 15 , further comprising a control system configured to control the shimming system such that shims are insertable at adjustable heights.

17 . The stone cutting system of claim 15 , further comprising a control system configured to control the shimming system such that shims are insertable at a plurality of heights within a single cutting operation.

18 . The stone cutting system of claim 10 , wherein the plurality of cutting wires are configured to pass through the plurality of kerfs in a first direction in a cutting phase and in a second direction opposite the first direction in a return phase thereby effecting continuous cutting of the unit of input material.

19 . A stone cutting system for cutting a stone block, the stone cutting system comprising:

a cutting station including:

a frame;

a lower conveyor including a first plurality of rollers and supported on the frame;

a middle conveyor including a second plurality of rollers, the middle conveyor being vertically adjustable on the frame; and

an upper conveyor including a third plurality of rollers;

at least one drive motor drivably connected to at least one of the first plurality of rollers, the second plurality of rollers, and the third plurality of rollers for advancing the stone block on one of the lower conveyor, the middle conveyor, and the upper conveyor;

a cutting assembly including:

a plurality of pulleys rotatable relative to the frame about a vertically extending axis;

a drive motor drivably connected to the plurality of pulleys; and

a plurality of cutting wires entrained on the plurality of pulleys such that rotation of the pulleys via the drive motor cycles the cutting wires,

wherein at least one of the first plurality of rollers, the second plurality of rollers, and the third plurality of rollers are configured to rotate thereby advancing the stone block toward the cutting wires such that the plurality of cutting wires cut a plurality of vertically spaced kerfs into the stone block and hence form a plurality of stone sections;

a spray system configured to spray a fluid near the kerfs to cool at least one of the plurality of stone sections and the cutting wires; and

a shimming system configured to automatically insert shims into the kerfs;

a loading lift including a carriage configured to raise the stone block to at least one of the middle conveyor and the upper conveyor;

an unloading lift including a carriage configured to lower the plurality of stone sections from at least one of the middle conveyor and the upper conveyor; and

a control system configured to activate the at least one drive motor of the cutting station, the drive motor of the cutting assembly, and the shimming system.