CN112247795B - Coil diameter period compensation method of diamond wire cutting equipment - Google Patents
Coil diameter period compensation method of diamond wire cutting equipment Download PDFInfo
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- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 86
- 239000010432 diamond Substances 0.000 title claims abstract description 86
- 238000000034 method Methods 0.000 title claims abstract description 44
- 238000005520 cutting process Methods 0.000 title claims abstract description 38
- 238000004804 winding Methods 0.000 claims abstract description 90
- 238000011084 recovery Methods 0.000 claims description 6
- 238000013461 design Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 238000012544 monitoring process Methods 0.000 abstract description 2
- 230000000712 assembly Effects 0.000 description 4
- 238000000429 assembly Methods 0.000 description 4
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- 238000012360 testing method Methods 0.000 description 3
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- QBPPRVHXOZRESW-UHFFFAOYSA-N 1,4,7,10-tetraazacyclododecane Chemical compound C1CNCCNCCNCCN1 QBPPRVHXOZRESW-UHFFFAOYSA-N 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
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- 230000002441 reversible effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B27/00—Other grinding machines or devices
- B24B27/06—Grinders for cutting-off
- B24B27/0633—Grinders for cutting-off using a cutting wire
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
- B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
- B65H75/34—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks specially adapted or mounted for storing and repeatedly paying-out and re-storing lengths of material provided for particular purposes, e.g. anchored hoses, power cables
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Abstract
The invention discloses a coil diameter period compensation method of diamond wire cutting equipment, which comprises the following steps: calculating the theoretical line consumption length of the diamond wire when the current wire running period is finished based on the preset wire return rate; real-time grabbing and calculating the actual wire consumption length of the diamond wire when the current wire running period is finished based on the winding and unwinding positions; calculating the difference between the actual line loss length and the theoretical line loss length to obtain a compensation value; and performing line running compensation in the next line running period of the diamond line by using the calculated compensation value. By the aid of the roll diameter period compensation method of the diamond wire cutting equipment, compensation values are introduced, wire consumption is compensated, the worn diamond wires are continuously recycled according to the pre-designed loss rate, monitoring and calibration of wire consumption can be conveniently achieved only through software programming, and production efficiency is improved.
Description
Technical Field
The invention belongs to the technical field of diamond wire cutting, and particularly relates to a roll diameter period compensation method of diamond wire cutting equipment.
Background
The diamond wire is taken as a typical tool for wire cutting and is widely applied to various cutting and cutting fields, the cutting of the diamond wire is realized by the reciprocating motion of the wire, the existing diamond wire cutting equipment enables the diamond wire to be sequentially wound on winding and unwinding assemblies at two sides by arranging wire arranging assemblies at two sides of a cutting area, the diamond wire performs a wire cutting process on the winding and unwinding assemblies at two sides along with the rotation of the winding and unwinding assemblies, certain loss is generated after the diamond wire cutting, the cutting quality can be ensured by replacing the wire after cutting for a period of time, the wire replacing process is complicated, the shutdown of the whole cutting production line can be caused, the production and cutting efficiency is greatly influenced, a diamond wire coil with larger winding thickness is initially arranged on the diamond wire cutting equipment, and each wire running period recovers a small section of diamond wire with the end part completing the winding and cutting task to a device, and the rest diamond wire continuously participates in the cutting task of the next wire running period, the wire running period comprises a wire running process and a wire returning process, the length of the diamond wire in the wire running process is the wire running length, the length of the diamond wire in the wire returning process is the wire returning length, the wire returning length at each time is designed to be smaller than the wire running length, the difference value between the wire running length and the wire returning length is the wire consumption, the wire consumption is gradually increased along with the continuous repetition of the wire running period, and finally the diamond wire is continuously lost, so that the diamond wire is continuously and circularly cut on the coil diameter, the larger diamond wire coil is continuously cut and recovered, the wire changing process is avoided for many times, the production efficiency is improved, but the influence of the factors such as the slippage of the diamond wire in the actual operation process cannot be controlled, the diamond wire can not be recovered according to the preset wire returning length at each time, and the diamond wire cannot be accurately recovered according to the preset requirement.
Accordingly, further developments and improvements are still needed in the art.
Disclosure of Invention
In order to solve the above problems, a method for compensating a coil diameter period of a diamond wire cutting device is proposed. The invention provides the following technical scheme:
a coil diameter period compensation method of diamond wire cutting equipment comprises the following steps:
calculating the theoretical line consumption length of the diamond wire when the current wire running period is finished based on the preset wire return rate;
real-time grabbing and calculating the actual wire consumption length of the diamond wire when the current wire running period is finished based on the winding and unwinding positions;
calculating a compensation value based on the obtained actual line loss length and the theoretical line loss length;
and performing line running compensation in the next line running period of the diamond line by using the calculated compensation value.
Further, a theoretical line loss length (run length (1-loop rate)) is obtained based on the loop rate, and the theoretical line loss length is an accumulated value of the recovery loss lengths of the diamond wires according to the design requirement of the loop rate.
Further, the actual consumed length of the wire is an integrated value of deviation lengths of the diamond wire on the winding and unwinding, and the deviation length is position deviation, namely winding and unwinding diameter 3.14/360.
Further, the position deviation obtaining method includes: the controller periodically acquires the angle position of the winding and unwinding motor and determines the winding and unwinding position based on the angle position.
Further, the controller acquires position data of the winding and unwinding motor at the current moment, and obtains a position deviation based on the position data acquired in the previous period.
Further, the method for obtaining the winding and unwinding diameter comprises the following steps: the controller obtains and judges the increase and decrease condition of the winding and unwinding diameter based on the reversing signal of the winding and unwinding motor and the winding and unwinding speed, and calculates the winding and unwinding diameter based on the increase and decrease condition of the winding and unwinding diameter.
Further, the method for judging the commutation signal of the flat cable motor comprises the following steps: the controller periodically acquires the position of the wire arranging motor, the wire arranging motor is preset with positive limit and negative limit and used for controlling the diamond wires to wind positively and negatively on the winding and unwinding coils, and when the wire arranging motor is just positioned at the switching position of the positive limit and the negative limit, the wire arranging motor is judged to be reversed.
Further, the method for obtaining the winding and unwinding diameter comprises the following steps: and calculating the winding and unwinding diameter after reversing based on the reversing signal of the winding and unwinding motor and the current winding and unwinding diameter.
Has the advantages that:
according to the compensation method for the coil diameter period of the diamond wire cutting equipment, the compensation value is introduced, the wire consumption is compensated, the worn diamond wire is continuously recycled according to the predesigned loss rate, the monitoring and calibration of the wire consumption can be conveniently realized only through software programming, and the production efficiency is improved.
Drawings
Fig. 1 is a schematic flow chart of a roll diameter period compensation method of diamond wire cutting equipment according to an embodiment of the present invention.
Detailed Description
In order to make the technical solutions of the present invention better understood, the following description of the technical solutions of the present invention with reference to the accompanying drawings of the present invention is made clearly and completely, and other similar embodiments obtained by a person of ordinary skill in the art without any creative effort based on the embodiments in the present application shall fall within the protection scope of the present application. In addition, directional terms such as "upper", "lower", "left", "right", etc. in the following embodiments are directions with reference to the drawings only, and thus, the directional terms are used for illustrating the present invention and not for limiting the present invention.
As shown in fig. 1, a method for compensating a coil diameter period of a diamond wire cutting device includes:
s100, calculating the theoretical line consumption length of the diamond wire when the current wire running period is finished based on a preset loop rate;
s200, real-time grabbing and calculating the actual wire consumption length of the diamond wire when the current wire running period is finished based on the winding and unwinding positions;
s300, calculating a compensation value based on the obtained actual line loss length and the theoretical line loss length;
and S400, performing line running compensation in the next line running period of the diamond line by using the calculated compensation value.
According to the method for compensating the coil diameter period of the diamond wire cutting equipment, a diamond wire coil with large winding thickness is initially installed on the diamond wire cutting equipment, a small section of diamond wire of which the end part has finished a cutting task is recycled from a winding device in each wire running period, the recycled part is called wire consumption, and the rest diamond wire continuously participates in the cutting task in the next wire running period, so that the diamond wire is continuously and circularly cut on the coil diameter, the large diamond wire coil is continuously cut and recycled, the process of wire changing for many times is avoided, and the production efficiency is improved. Because the actual running length of the diamond wire in one running period is unstable, the length of the wound and unwound wire can be controlled only by adjusting the rotating speed of the wound and unwound wire on the wound and unwound wire, and the wound and unwound wire length also changes along with the change of the diameter of the wound and unwound wire, meanwhile, uncertain factors such as slippage and the like frequently occur in the movement process of the diamond wire between the wound and unwound wire to interfere with the finally recovered wire consumption length, the concept of wire consumption compensation is introduced, the loss of the diamond wire is calculated out into a theoretical wire consumption length through an empirical value, so that various parameters required by the wound and unwound wire during cutting of the diamond wire can be conveniently set according to the theoretical wire consumption length, the recovered actual wire consumption length of the diamond wire can be converted through the deflection difference of the recovered wire angle, therefore, the difference between the calculated actual wire consumption length and the theoretical wire consumption length is a compensation value, and the calculated compensation value is used for compensating the wire consumption in the next running period, and further, the wire consumption is guaranteed to finish the diamond wire recovery task according to the pre-designed theoretical wire consumption, so that the loss of the diamond wire is effectively managed, and a user is conveniently reminded of the replacement time of the diamond wire coil.
Further, the wire running period comprises a wire running process and a wire returning process, the length of the diamond wire in the wire running process is the wire running length, the length of the diamond wire in the wire returning process is the wire returning length, a theoretical wire returning length (wire running length) is obtained based on the wire returning rate, a theoretical wire consuming length (wire running length) (1-wire returning rate) is obtained, and the actual wire returning length (theoretical wire returning length + compensation value) is calculated. One wire running period is usually measured by taking one wire running length as a measurement unit, the diamond wire firstly moves by one wire running length in one wire running period and is looped back according to the theoretical wire consumption length, but the actual looped back length is smaller than the theoretical looped back length due to the situations of slipping and the like in the actual situation, so that the diamond wire cannot be recovered according to the preset recovery progress, a compensation value is introduced, the completed current wire running period is compensated, and the diamond wire is recovered according to the preset recovery progress.
Further, the theoretical line loss length is an integrated value of the recovery loss length of the diamond wire according to the design requirement of the loop rate, the actual line loss length is an integrated value of the deviation length of the diamond wire on the winding and unwinding, and the deviation length is position deviation winding and unwinding diameter 3.14/360. Because the diamond wire is in a winding state on winding and unwinding, the winding and unwinding diameter is kept unchanged in the winding and unwinding reversing period, the diameter can be calculated, the rotation angle of the winding and unwinding can be obtained, and further the position deviation value can be obtained, so that the deviation length of the diamond wire on the winding and unwinding is deduced through an arc length calculation formula.
Further, the position deviation obtaining method comprises the following steps: the controller periodically acquires the angle position of the winding and unwinding motor and determines the winding and unwinding position based on the angle position.
Further, the controller acquires position data of the winding and unwinding motor at the current moment, and obtains a position deviation based on the position data acquired in the previous period.
Further, the method for acquiring the winding and unwinding diameter comprises the following steps: the controller obtains and judges the increase and decrease condition of the winding and unwinding diameter based on the reversing signal of the winding and unwinding motor and the winding and unwinding speed, and calculates the winding and unwinding diameter based on the increase and decrease condition of the winding and unwinding diameter. The winding and unwinding motor tightly winds diamond wires side by side on winding and unwinding, and after winding of one layer is finished, the diamond wires can be wound on the basis of the original winding diameter, so that the winding and unwinding diameter can be changed along with winding of the winding wire, the change quantity is the diameter of the diamond wires, when the winding and unwinding motor starts reversing, the change of the winding and unwinding diameter is directly influenced by the time node for increasing or decreasing the winding and unwinding diameter.
Further, the method for judging the commutation signal of the flat cable motor comprises the following steps: the controller periodically acquires the position of the wire arranging motor, the wire arranging motor is preset with positive limit and negative limit and used for controlling the diamond wire to wind positively and negatively on the winding and unwinding coil, and when the wire arranging motor is just positioned at the switching position of the positive limit and the negative limit, the wire arranging motor is judged to be reversed.
Further, the method for acquiring the winding and unwinding diameter comprises the following steps: and calculating the winding and unwinding diameter after reversing based on the reversing signal of the winding and unwinding motor and the current winding and unwinding diameter.
The specific method comprises the following steps: setting the forward rotation speed of the winding and unwinding motor to be a positive value, setting the reverse rotation speed to be a negative value, and calculating the winding and unwinding speed based on the rotation speed and the rotation direction of the winding and unwinding motor;
when the winding and unwinding speed is a positive value, judging the winding and unwinding diameter increasing state, wherein the current winding and unwinding diameter is equal to the diameter before reversing plus the diameter of the diamond wire;
when the winding and unwinding speed is a negative value, the winding and unwinding diameter is judged to be in a reduced state, and the current winding and unwinding diameter is equal to the diameter before reversing-diamond wire diameter.
Period Compensation calculation embodiments
Setting the theoretical line consumption length at the end of the first line running period as S1The theoretical line loss length of the Nth line running period is SNThe actual line consumption length at the end of the first running period is T1The actual line consumption length at the end of the first running period is TNThe compensation value at the end of the first track period is E1The compensation value at the end of the Nth line running period is ENCalculating the actual loop length of the second wire running period to be C when the first wire running period is ended1Calculating the actual loop length of the N +1 th running period as C when the Nth running period is overNThe loop rate of the equipment is K, the wire running period is equal to the theoretical wire running length per period and is B, then:
the theoretical line loss length at the end of the first line running period is: s1＝(1-K)*B；
The theoretical line loss length at the end of the Nth line running period is as follows: sN＝(1-K)*B*N；
The compensation value at the end of the first tracking period is: e1＝T1-S1＝T1-(1-K)*B；
The compensation value at the end of the Nth line running period is as follows: eN＝TN-SN＝TN-(1-K)*B*N；
The actual loop length of the second routing period should be: c1＝B*K+E1＝B*K+T1-(1-K)*B；
The actual loop length of the N +1 th routing period should be: cN＝B*K+EN＝B*K+TN-(1-K)*B*N；
When the line running period is 300 meters, the loop rate is 99 percent, and the measured actual line loss length after the first period is finished is 5 meters:
theoretical line loss length S1＝S1(1-K) × B ═ 300 ═ 1-99% > -3 meters;
compensation value E1＝T1-S1＝T1- (1-K) ═ B ═ 5-3 ═ 2 meters;
the actual loop length of the second wire running period is C1＝B*K+E1＝B*K+T1- (1-K) × B ═ 300 × 99% +2 ═ 299 m.
That is to say, the wire running period is 300 meters, the wire return rate is 99%, and if the wire starting time is 0 meter, the wire is theoretically 300 meters for paying off and 297 meters for taking up, so that 3 meters of wire are consumed each time, one wire running period is finished, that is, the wire return is finished, the diamond wire should stop at the position of 3 meters in length, if there is no length deviation caused by actual conditions such as slipping, the wire return is 300 × 99% to 297 meters, but because the actual conditions such as slipping cause deviation, a plurality of wire return points or a few wire return points are performed to compensate the deviation in the wire return of the next wire running period, so that the actual wire return length is compensated by calculating the compensation value, and finally the wire running length of the second wire running period is 300 meters and the wire return length is 299 meters.
Practical line loss length calculation embodiment
Setting the periodic grabbing time to be 1 millisecond, and the first periodic reeling and unreeling diameter to be D1The diameter of the rice and the Nth cycle winding and unwinding is DNThe angle of the first period of winding and unwinding is delta 1, the angle of the Nth period of winding and unwinding is delta N, and the distance of the first period of winding and unwinding is L1The distance traveled by the Nth cycle is LNThe total length of the running line is L.
Length L of wire passed in the first cycle1＝Δ1*D1*3.1415/360；
Length L of line passed by Nth cycleN＝ΔN*DN*3.1415/360；
The total actual length of the wire loss that is passed is L ═ L1+L2+……+LN；
In practice, 10 periods of data are captured, and the length units are meters:
diameter D1-D10Are respectively as(0.180，0.180，0.180，0.180，0.183，0.183，0.183，0.183，0.186，0.186)；
The deviation angles Δ 1- Δ 10 are (110.2, 120.2, 130.5, 110.5, 112.2, 113.6, 123.5, 145.3, 126.4, 129.8), respectively;
the length of each cycle walk is calculated, leaving four decimal places:
L1＝0.18*110.2*3.1415/360＝0.1731；
L2＝0.18*120.2*3.1415/360＝0.1888；
L3＝0.18*130.5*3.1415/360＝0.2050；
L4＝0.18*110.5*3.1415/360＝0.1736；
L5＝0.183*112.2*3.1415/360＝0.1792；
L6＝0.183*113.6*3.1415/360＝0.1814；
L7＝0.183*123.5*3.1415/360＝0.1972；
L8＝0.183*145.3*3.1415/360＝0.2320；
L9＝0.186*126.4*3.1415/360＝0.2051；
L10＝0.186*129.8*3.1415/360＝0.2106；
calculating the total length:
L＝L1+L2+L3+L4+L5+L6+L7+L8+L9+L10
0.1731+0.1888+0.2050+0.1736+0.1792+0.1814+0.1972+0.2320+0.2051+0.2106 is 1.9460 m.
The whole winding line test result: the length of the whole coil is 10000 m, the coil is changed when the coil amount is remained 800 m due to unexpected reasons, more than 400 m of the coil is remained after calculation according to the diameter of the coil, and the calculated coil amount is smaller than the actual coil amount due to the fact that the coil is broken in the cutting process. The difference between the actual thread quantity of the whole winding line and the calculated thread quantity is within 500 meters.
Line loss test results: the on-site test machine actually uses 3400 meter of wire, totally cuts 92 rods, the abnormal condition occurs seven times (the abnormal condition is wire breakage or periodic resetting), the on-site process theoretical wire consumption is 29.1 meters, the integral theoretical wire consumption is about 800 meters different from the actual wire consumption, according to on-site statistics, more than 100 meters of wire can be wasted each time of abnormality, and the theoretical wire consumption is not greatly different from the actual wire consumption on the whole.
The present invention has been described in detail, and it should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
Claims (6)
1. A coil diameter period compensation method of diamond wire cutting equipment is characterized by comprising the following steps:
calculating the theoretical line consumption length of the diamond wire when the current wire running period is finished based on the preset wire return rate;
real-time grabbing and calculating the actual wire consumption length of the diamond wire when the current wire running period is finished based on the winding and unwinding positions;
calculating a compensation value based on the obtained actual line loss length and the theoretical line loss length;
carrying out line running compensation in the next line running period of the diamond line by using the calculated compensation value;
obtaining a theoretical line loss length (running line length) on the basis of a loop rate, wherein the theoretical line loss length is an accumulated value of the recovery loss length of the diamond wire according to the design requirement of the loop rate;
the actual wire consumption length is the accumulated value of the deviation length of the diamond wire on winding and unwinding, and the deviation length is position deviation winding and unwinding diameter 3.14/360.
2. A roll diameter period compensation method of a diamond wire cutting device according to claim 1, wherein the position deviation obtaining method is: the controller periodically acquires the angle position of the winding and unwinding motor and determines the winding and unwinding position based on the angle position.
3. The roll diameter period compensation method of a diamond wire cutting device according to claim 2, wherein the controller obtains position data of a winding and unwinding motor at the present time, and obtains a position deviation based on the position data obtained in the previous period.
4. The method for compensating the coil diameter period of the diamond wire cutting equipment according to claim 1, wherein the method for obtaining the winding and unwinding diameter comprises the following steps: the controller obtains and judges the increase and decrease condition of the winding and unwinding diameter based on the reversing signal of the winding and unwinding motor and the winding and unwinding speed, and calculates the winding and unwinding diameter based on the increase and decrease condition of the winding and unwinding diameter.
5. The coil diameter period compensation method of diamond wire cutting equipment according to claim 4, wherein the commutation signal judgment method of the traverse motor is as follows: the controller periodically acquires the position of the wire arranging motor, the wire arranging motor is preset with positive limit and negative limit and used for controlling the diamond wires to wind positively and negatively on the winding and unwinding coils, and when the wire arranging motor is just positioned at the switching position of the positive limit and the negative limit, the wire arranging motor is judged to be reversed.
6. The method for compensating the coil diameter period of the diamond wire cutting equipment according to claim 4, wherein the method for acquiring the winding and unwinding diameter comprises the following steps: and calculating the winding and unwinding diameter after reversing based on the reversing signal of the winding and unwinding motor and the current winding and unwinding diameter.
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