CN114654595B - Cutting method and system for reducing fault rate of cutting machine - Google Patents
Cutting method and system for reducing fault rate of cutting machine Download PDFInfo
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- CN114654595B CN114654595B CN202210366047.4A CN202210366047A CN114654595B CN 114654595 B CN114654595 B CN 114654595B CN 202210366047 A CN202210366047 A CN 202210366047A CN 114654595 B CN114654595 B CN 114654595B
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- 238000005520 cutting process Methods 0.000 title claims abstract description 211
- 238000000034 method Methods 0.000 title claims abstract description 54
- 238000004804 winding Methods 0.000 claims abstract description 80
- 239000011521 glass Substances 0.000 claims description 14
- 239000002419 bulk glass Substances 0.000 claims description 6
- 238000001304 sample melting Methods 0.000 claims description 6
- 229910003460 diamond Inorganic materials 0.000 claims description 4
- 239000010432 diamond Substances 0.000 claims description 4
- 238000007493 shaping process Methods 0.000 claims description 4
- 239000006060 molten glass Substances 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 2
- 238000012545 processing Methods 0.000 abstract description 7
- 230000000694 effects Effects 0.000 description 3
- 238000003754 machining Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/06—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with reciprocating saw-blades
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/06—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with reciprocating saw-blades
- B28D1/068—Components, e.g. guiding means, vibrations damping means, frames, driving means, suspension
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
- Y02P40/57—Improving the yield, e-g- reduction of reject rates
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mining & Mineral Resources (AREA)
- Processing Of Stones Or Stones Resemblance Materials (AREA)
Abstract
The invention discloses a cutting method and a cutting system for reducing the failure rate of a cutting machine, belonging to the technical field of wire cutting processing, wherein the method comprises the steps of setting cutting process parameters according to the performance of a product to be cut; calculating the winding length of the wire saw according to the cutting parameters; winding the wire saw according to the wire saw winding length and the cutting parameters; and after winding, cutting the product to be cut according to the process requirement. The wire saw winding length of the wire saw is calculated before the wire saw is cut by the cutting machine, and the wire saw of the cutting machine is wound according to the wire saw winding length, so that the wire arrangement distance and the swinging rod tension of the cutting machine are kept uniform with the wire arrangement distance and the wire tension of the wire saw, and further the problem of cutting machine faults such as swinging rod shaft alarming and wire breakage caused by non-uniformity of the wire arrangement distance and the swinging rod tension of the cutting machine and the cutting process in the cutting process of the cutting machine is solved.
Description
Technical Field
The invention belongs to the technical field of wire cutting, relates to a cutting method and a cutting system for reducing the failure rate of a cutting machine, and particularly relates to a cutting method and a cutting system for reducing the failure rate of a cutting machine for wire cutting.
Background
In the glass processing process, the melted bulk glass is cut into single glass by a single-wire cutting machine and a multi-wire cutting machine. Therefore, single wire and multi-wire cutting processes are particularly important. The wire cutting machine has the characteristics of high machining precision, high cleanliness, high cutting speed and the like, and is therefore commonly used for machining complex cavities and curved surfaces of various conductors such as various grinding tools, precise parts, electrodes and the like.
Because the wire arrangement distance and the wire arrangement tension of a manufacturer during wire arrangement of the diamond wire saw are not uniform with the wire arrangement distance and the wire arrangement tension of single-wire or multi-wire cutting machine equipment, the problem of broken wire fault of the cutting machine and the problem of alarm of a swinging rod of the cutting machine are easily caused in the using process, wherein the broken wire fault is common fault of the wire cutting machine, and the broken wire fault accounts for 70% of the fault rate of the wire cutting equipment. When the wire cutting machine breaks, the control system can display an alarm code to remind operators that the wire cutting machine breaks.
Disclosure of Invention
The invention aims to solve the problems in the prior art, and provides a cutting method and a cutting system for reducing the fault rate of a cutting machine, which can keep the tension of a swinging rod and the line spacing of the cutting machine uniform in the cutting process of the cutting machine and effectively avoid the problem of broken line fault of the cutting machine.
In order to achieve the purpose, the invention is realized by adopting the following technical scheme:
the invention provides a cutting method for reducing the failure rate of a cutting machine, which comprises the following steps:
setting cutting process parameters according to the performance of the product to be cut;
calculating the wire saw winding length according to the cutting process parameters;
winding the wire saw according to the wire saw winding length and the cutting process parameters;
and after winding, cutting the product to be cut according to the process requirement.
Preferably, the cutting process parameters include line speed, cutting speed, new line speed, and reciprocation time.
Preferably, the method for setting cutting process parameters according to the performance of the product to be cut is as follows:
determining cutting speed, new line incoming speed, line speed and reciprocating time according to the hardness of the product to be cut;
and determining the cutting time according to the cutting speed and the cutting height of the product to be cut.
Preferably, the method for determining the cutting time according to the cutting speed and the height of the product to be cut comprises the following steps:
T＝h/V h (1)
wherein h is the cutting height of the product to be cut, T is the cutting time, V h Is the cutting speed.
Preferably, according to the cutting process parameters, the method for calculating the wire saw winding length comprises the following steps:
L＝V 0 *T+V*t/2 (2)
wherein L is the winding length of the wire saw, V 0 The line feeding speed is the new line feeding speed, V is the line feeding speed, T is the cutting time, and T is the reciprocating time.
Preferably, the method for winding the wire saw according to the wire saw winding length and the cutting process parameters comprises the following steps:
according to the actual tension required during cutting, the wire saw on a new wire paying-off wheel of the cutting machine is paid out to a wire inlet wheel for winding according to the wire saw winding length;
after the wire winding of the wire inlet wheel is finished, the wire saw wound on the wire inlet wheel is reversely discharged to a new wire paying-off wheel for reverse winding, so that the wire arrangement distance and the wire tension of the wire saw are unified with the wire arrangement distance and the swinging rod tension of the cutting machine.
Preferably, the product to be cut is a post-melting bulk glass.
Preferably, after the winding is finished, the method for cutting the product to be cut comprises the following steps:
shaping the block glass after sample melting by adopting single-wire cutting;
setting cutting process parameters according to the properties of the shaped molten bulk glass;
calculating the wire saw winding length according to the cutting process parameters;
and according to the wire saw winding length and the cutting process parameters, the wire saw of the multi-wire cutting machine winds, and after winding is finished, multi-wire cutting is carried out on the shaped molten glass block, so that cutting is completed.
Preferably, the wire saw is a diamond wire saw.
The invention also provides a cutting system for reducing the failure rate of the cutting machine, which comprises:
the cutting process parameter setting module is used for setting cutting process parameters according to the performance of the product to be cut;
the wire saw winding length calculation module is used for calculating the wire saw winding length according to the cutting process parameters;
the wire saw winding module is used for controlling the cutting machine to wind the wire saw according to the wire saw winding length and the cutting process parameters;
and the cutting module is used for controlling the cutting machine to cut the product to be cut according to the process requirement after winding is finished.
Compared with the prior art, the invention has the following beneficial effects:
the invention provides a cutting method for reducing the fault rate of a cutting machine, which is characterized in that cutting parameters are designed according to the performance of a product to be cut before the product to be cut is cut by wires, the wire winding length of a wire saw is obtained according to the cutting parameters, and the wire winding is carried out according to the wire winding length, so that the wire arrangement distance and the swinging rod tension of the cutting machine, namely the wire winding tension, the wire arrangement distance and the wire tension of the wire saw can be kept uniform in the running process of the cutting machine, the problem of wire breakage fault of the cutting machine in the running process is reduced, the fault rate of equipment can be effectively reduced, the working efficiency of the equipment is improved, the maintenance cost of the equipment is reduced, and the method is simple in principle and easy to operate.
The invention provides a cutting system for reducing the failure rate of a cutting machine, which can realize parameter setting of the whole cutting method, wire saw wire winding length calculation, overall control of wire saw wire winding and cutting processes through the arrangement of a cutting process parameter setting module, a wire saw wire winding length calculation module, a wire saw wire winding module and a cutting module, is simple to operate, can effectively improve the processing efficiency of products, and reduces the operation intensity of operators.
Drawings
For a clearer description of the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present invention and should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of a cutting method for reducing failure rate of a cutting machine according to the present invention.
FIG. 2 is a block diagram of a cutting system for reducing the failure rate of a cutting machine according to the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the invention, as presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures.
In the description of the embodiments of the present invention, it should be noted that, if the terms "upper," "lower," "horizontal," "inner," and the like indicate an azimuth or a positional relationship based on the azimuth or the positional relationship shown in the drawings, or the azimuth or the positional relationship in which the inventive product is conventionally put in use, it is merely for convenience of describing the present invention and simplifying the description, and does not indicate or imply that the apparatus or element to be referred to must have a specific azimuth, be configured and operated in a specific azimuth, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used merely to distinguish between descriptions and should not be construed as indicating or implying relative importance.
Furthermore, the term "horizontal" if present does not mean that the component is required to be absolutely horizontal, but may be slightly inclined. As "horizontal" merely means that its direction is more horizontal than "vertical", and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.
In the description of the embodiments of the present invention, it should also be noted that, unless explicitly specified and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" should be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
The invention is described in further detail below with reference to the attached drawing figures:
referring to fig. 1, the invention provides a cutting method for reducing the failure rate of a cutting machine, comprising the following steps:
according to the performance of the product to be cut, setting cutting technological parameters: in the embodiment, the block glass after sample melting is used as a raw material, and the diamond wire saw is used for wire cutting. Firstly, determining the linear speed, the cutting speed, the new linear speed and the reciprocating time of cutting parameters according to the hardness and the cutting height of the block glass after sample melting; then, according to the cutting speed and the cutting height, the cutting time is calculated by the following method:
T＝h/V h (1)
wherein h is the cutting height of the product to be cut, T is the cutting time, V h Is the cutting speed.
According to the cutting technological parameters, calculating the wire saw winding length: according to the calculated cutting time, the cutting speed in the technological parameters and the cutting height of the block glass after the molten sample is to be cut, calculating the wire saw winding length by the following method:
L＝V 0 *T+V*t/2 (2)
wherein L is the winding length of the wire saw, V 0 The line feeding speed is the new line feeding speed, V is the line feeding speed, T is the cutting time, and T is the reciprocating time.
Winding the wire saw according to the wire saw winding length and the cutting parameters, and paying out the wire saw of the new wire paying-off wheel to the wire inlet wheel for winding according to the calculated wire saw winding length and the actual wire tension;
after winding is finished, cutting the product to be cut: the reverse winding is carried out according to the actual tension required during cutting, so that the wire arrangement distance and the swing rod tension are kept uniform, and the product to be cut is cut; according to the invention, single-wire cutting is firstly carried out on the block glass after sample melting, shaping is carried out on the block glass, then multi-wire cutting is carried out on a product after single-wire cutting, and slicing is carried out.
For example: the method comprises the steps that a block glass to be cut after a molten sample is cut is 70mm in thickness, single-wire cutting is to be carried out on the block glass, the linear speed is set to be 1000mm/min according to the hardness of the block glass, the new linear inlet speed of the block glass is set to be 0.5mm/min at the cutting speed of 1.5mm/min, the wire saw tension is 30N, the reciprocating time is 3min, and then the cutting time T is calculated according to a formula (1):
70mm/1.5min＝46.67min。
the wire saw winding length L can be calculated according to formula (2) as:
0.5mm/min×46.67min+1000mm/min×3min÷2＝1524mm。
and the actual tension of the wire is 30N, the wire saw of the new wire paying-off wheel is paid out to the wire inlet wheel for winding according to the wire saw winding length of 1524mm, and after the winding is finished, the wire saw of the wire inlet wheel is paid off to the new wire paying-off wheel for reverse winding;
shaping the block glass after sample melting by adopting single-wire cutting after winding; setting cutting process parameters according to the properties of the shaped molten bulk glass; calculating the wire saw winding length according to the cutting process parameters; and according to the wire saw winding length and the cutting process parameters, the wire saw of the multi-wire cutting machine winds, and after winding is finished, multi-wire cutting is carried out on the shaped molten glass block, so that cutting is completed.
Referring to fig. 2, the present invention further provides a cutting system for reducing a failure rate of a cutting machine, including:
the cutting process parameter setting module comprises all data of corresponding parameters of all the product performances to be cut in the past and is used for setting the cutting process parameters according to the product performances to be cut;
the new wire winding length calculation module is used for executing a calculation process according to the cutting parameters and calculating the new wire winding length;
the new wire winding module is used for controlling the cutting machine to wind the new wire according to the winding length and the cutting parameters;
and the cutting module is used for controlling the cutting machine to cut the product to be cut after winding is finished.
The method is suitable for single-wire cutting and is also suitable for a cutting mode of reducing the fault rate by multi-wire cutting, when winding, winding can be carried out before each cutting according to the process requirement, and winding can also be carried out for a plurality of times in the whole cutting process, preferably, according to different processes, the winding operation is carried out before each processing for better reducing the fault rate.
With reference to the following table, through practical operation verification, the comparison of the effects of the traditional cutting method and the improved cutting method is found:
traditional cutting method and improved cutting method effect comparison table
The cutting machine is directly used for processing, the probability of broken line fault can reach 70%, and by utilizing the method, the winding process is carried out before processing and cutting, so that the wire arrangement distance of the cutting machine, the tension of the swinging rod, the wire arrangement distance and the tension of the wire saw can be kept uniform, the probability of broken line fault problem in the processing process can be basically reduced to below 3%, and the method has remarkable effect of reducing the fault rate of the cutting machine.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. The cutting method for reducing the failure rate of the cutting machine is characterized by comprising the following steps of:
setting cutting process parameters according to the performance of the product to be cut; the cutting process parameters comprise linear speed, cutting speed, new linear speed and reciprocating time;
according to the cutting technological parameters, calculating the wire saw winding length, wherein the method comprises the following steps:
wherein L is the winding length of the wire saw, V 0 The line feeding speed is the new line feeding speed, V is the line speed, T is the cutting time, and T is the reciprocating time;
according to the wire saw winding length and cutting technological parameters, the wire saw is wound, and the method comprises the following steps:
according to the actual tension required during cutting, the wire saw on a new wire paying-off wheel of the cutting machine is paid out to a wire inlet wheel for winding according to the wire saw winding length;
after the wire winding of the wire inlet wheel is finished, reversely paying out the wire saw wound on the wire inlet wheel to a new wire paying-off wheel for reverse winding, so that the wire arrangement distance and the wire tension of the wire saw are unified with the wire arrangement distance and the swinging rod tension of the cutting machine;
and after winding, cutting the product to be cut according to the process requirement.
2. The cutting method for reducing the failure rate of a cutting machine according to claim 1, wherein the method for setting the cutting process parameters according to the properties of the product to be cut is as follows:
determining cutting speed, new line incoming speed, line speed and reciprocating time according to the hardness of the product to be cut;
and determining the cutting time according to the cutting speed and the cutting height of the product to be cut.
3. The cutting method for reducing the failure rate of a cutting machine according to claim 2, wherein the method for determining the cutting time according to the cutting speed and the height of the product to be cut is as follows:
wherein h is the cutting height of the product to be cut, T is the cutting time, V h Is the cutting speed.
4. A cutting method for reducing failure rate of a cutting machine according to any one of claims 1 to 3, wherein the product to be cut is a post-melting bulk glass.
5. The cutting method for reducing the failure rate of a cutting machine according to claim 4, wherein after the winding is finished, the method for cutting the product to be cut is as follows:
shaping the block glass after sample melting by adopting single-wire cutting;
setting cutting process parameters according to the properties of the shaped molten bulk glass;
calculating the wire saw winding length according to the cutting process parameters;
and according to the wire saw winding length and the cutting process parameters, the wire saw of the multi-wire cutting machine winds, and after winding is finished, multi-wire cutting is carried out on the shaped molten glass block, so that cutting is completed.
6. The cutting method for reducing the failure rate of a cutting machine according to claim 5, wherein the wire saw is a diamond wire saw.
7. A cutting system for reducing the failure rate of a cutting machine for implementing the cutting method according to any one of claims 1 to 6, comprising:
the cutting process parameter setting module is used for setting cutting process parameters according to the performance of the product to be cut;
the wire saw winding length calculation module is used for calculating the wire saw winding length according to the cutting process parameters;
the wire saw winding module is used for controlling the cutting machine to wind the wire saw according to the wire saw winding length and the cutting process parameters;
and the cutting module is used for controlling the cutting machine to cut the product to be cut according to the process requirement after winding is finished.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210366047.4A CN114654595B (en) | 2022-04-08 | 2022-04-08 | Cutting method and system for reducing fault rate of cutting machine |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210366047.4A CN114654595B (en) | 2022-04-08 | 2022-04-08 | Cutting method and system for reducing fault rate of cutting machine |
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| Publication Number | Publication Date |
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| CN114654595A CN114654595A (en) | 2022-06-24 |
| CN114654595B true CN114654595B (en) | 2024-02-23 |
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0994755A (en) * | 1995-10-02 | 1997-04-08 | Toyo A Tec Kk | Wire tension controller in wire saw |
| JP2018051741A (en) * | 2016-09-30 | 2018-04-05 | コマツＮｔｃ株式会社 | Wire saw and method for driving wire saw |
| CN109304819A (en) * | 2018-11-27 | 2019-02-05 | 扬州荣德新能源科技有限公司 | A kind of crystalline silicon blocks high efficiency cutting method |
| CN109834848A (en) * | 2019-03-22 | 2019-06-04 | 台州职业技术学院 | A kind of saw blade cutting machine and scroll saw method of controlling rotation |
| CN209365073U (en) * | 2018-11-30 | 2019-09-10 | 宁波钜德精工机械有限公司 | Sapphire Buddha's warrior attendant wire cutting machine |
| CN113065235A (en) * | 2021-03-18 | 2021-07-02 | 燕山大学 | Method for calculating external load of wire winding wheel of multi-wire cutting machine |
-
2022
- 2022-04-08 CN CN202210366047.4A patent/CN114654595B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0994755A (en) * | 1995-10-02 | 1997-04-08 | Toyo A Tec Kk | Wire tension controller in wire saw |
| JP2018051741A (en) * | 2016-09-30 | 2018-04-05 | コマツＮｔｃ株式会社 | Wire saw and method for driving wire saw |
| CN109304819A (en) * | 2018-11-27 | 2019-02-05 | 扬州荣德新能源科技有限公司 | A kind of crystalline silicon blocks high efficiency cutting method |
| CN209365073U (en) * | 2018-11-30 | 2019-09-10 | 宁波钜德精工机械有限公司 | Sapphire Buddha's warrior attendant wire cutting machine |
| CN109834848A (en) * | 2019-03-22 | 2019-06-04 | 台州职业技术学院 | A kind of saw blade cutting machine and scroll saw method of controlling rotation |
| CN113065235A (en) * | 2021-03-18 | 2021-07-02 | 燕山大学 | Method for calculating external load of wire winding wheel of multi-wire cutting machine |
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