JP2020110883A - Band saw - Google Patents

Abstract

To provide a band saw that enables an operator to perform a cutting operation under preferable conditions without know-how of mechanical cutting that a skilled operator has through a wealth of experience.SOLUTION: A band saw 10 comprising cutting means 14 which has a saw blade 14a and feed means 16 which moves the cutting means 14 comprises: swarf removing means 18 which removes swarf sticking on the saw blade 14a; a swarf receiving plate 22 which is arranged below the swarf removing means 18 and sends received swarf downstream; imaging means 24 which images swarf collected on the swarf receiving plate 22; determining means 26 which compares swarf included in image data obtained through the imaging by the imaging means 24 with teacher data to classify the swarf included in the image data into a plurality of types, and selects a type having the largest content rate; and control means 28 which controls, based upon the type selected by the determining means 26, at least one of a rotating speed and a feeding speed of the saw blade 14a.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a band saw for cutting a large structure using an endless saw blade.

In the case of power plant remodeling and decommissioning work, mechanical cutting with a band saw or the like is often used to cut waste materials generated from the construction from the viewpoint of fire prevention. However, in mechanical cutting, unless proper operating conditions are taken according to the material and shape of the object to be cut, the cutting efficiency deteriorates, the saw blade is prematurely deteriorated, and the chips become extremely hot. Safety issues can also arise.

For this reason, in mechanical cutting, a veteran engineer with abundant experience adjusts the rotation speed and feed speed of the band saw appropriately so as to satisfy appropriate operating conditions. However, in recent years, there is a shortage of such veteran engineers at various construction sites, and the number of veteran engineers is decreasing.

In view of these problems, a technique disclosed in Patent Document 1 is known as one of the techniques for solving the problem that occurs during band saw operation. The technique disclosed in Patent Document 1 is a technique that suppresses noise during cutting by reducing chatter vibration generated in a saw blade during cutting with a band saw. The specific method is to intentionally generate vibration having a phase different from the chatter vibration and cancel the chatter vibration.

Further, as a technique for estimating the state of the machine tool, a technique disclosed in Patent Document 2 is known. The technique disclosed in Patent Document 2 relates to a cutting machine and estimates the state of a tool based on the scattering state of chips generated during cutting and the color.

JP, 2007-144624, A JP, 2018-138327, A

According to the technique disclosed in Patent Document 1, it is possible to reduce noise generated during cutting. However, the control of the rotation speed and the feed speed of the band saw at the time of cutting must be based on empirical values. Further, according to the technique disclosed in Patent Document 2, the state of the tool in the cutting machine can be estimated. However, in the band saw, the range in which the saw blade and the cutting target are in contact with each other changes depending on the cutting target. Therefore, it is difficult to detect the scattered state of chips.

In the present invention, it is possible to solve the above problems and provide a band saw capable of performing a cutting operation under suitable conditions without the know-how of a mechanical cutting that an expert has gained through a wealth of experience. To aim.

A band saw according to the present invention for achieving the above object is a cutting means having an endless saw blade, a pair of wheels around which the saw blade is wound, and a rotation motor that is connected to one of the wheels and is driven to rotate. In a band saw provided with: The chip receiving plate that receives and flows to the downstream side, the image capturing unit that captures the chips accumulated in the chip receiving plate, the chip included in the image data captured by the image capturing unit, and the teacher data are compared to obtain the image. The chips included in the data are divided into a plurality of types, and a determination unit that selects the type with the highest content ratio, based on the type selected by the determination unit, the rotation speed of the cutting unit and the feed of the feeding unit. And a control unit that controls at least one of the speeds.

Further, in the band saw having the above characteristics, the type of the chips is determined based on the shape and color of the chips. By having such a feature, the chip type can be easily patterned.

Further, in the band saw having the above characteristics, the control means changes the rotation speed or the feed speed according to the content ratio of the type of the chips included in the image data determined by the determination means. The proportions can be different. With such a feature, it is possible to shorten the time required to converge to an appropriate operating state.

According to the band saw having the above-mentioned characteristics, it is possible to perform the cutting work under suitable conditions without the know-how of mechanical cutting that an expert has gained through a wealth of experience.

It is a front view showing the composition of the band saw concerning an embodiment. It is a top view showing the composition of the band saw concerning an embodiment. It is a right side view which shows the structure of the band saw which concerns on embodiment. It is a technical data of Starrett Inc. showing the relationship between chip properties and cutting conditions.

Hereinafter, embodiments of a band saw according to the present invention will be described in detail with reference to the drawings. The embodiment described below is an example of a preferred embodiment for carrying out the present invention, and even if a part of the configuration is modified after having the characteristic configuration, the present invention Can be considered as a part of.

[Structure of band saw]
The configuration of the band saw according to the present embodiment will be described with reference to FIGS. 1 to 3. In the drawings, FIG. 1 is a front view showing a configuration of a band saw according to an embodiment, FIG. 2 is a plan view thereof, and FIG. 3 is a right side view thereof.

The band saw 10 according to the present embodiment includes a frame 12, a cutting unit 14, a feeding unit 16, a chip removing unit 18, a chip box 20, a chip receiving plate 22, an imaging unit 24, a determining unit 26, and a control unit 28.

[Basic configuration]
The frame 12 is an element serving as a base for supporting and arranging the cutting means 14, the feeding means 16 and the like, the details of which will be described later. In the case of this embodiment, it has the upper frame 12a, the support|pillar 12b, and the lower frame 12c. The upper frame 12 a is arranged above the frame 12. The upper frame 12a is configured by combining a width direction beam (a beam in the longitudinal direction) 12a1 and a thickness direction beam 12a2 arranged so as to be orthogonal to the width direction beam 12a1 in a frame shape. Therefore, the upper frame 12a is configured to have a substantially rectangular shape in a plan view.

The columns 12b are elements that support the upper frame 12a, and are connected to four points (approximately four corners) of the upper frame 12a. Therefore, four columns 12b are arranged for one upper frame. Guide rails 12b1 for moving up and down the cutting means 14, which will be described in detail later, are provided on the outside of the columns 12b, respectively.

The lower frame 12c is located below the frame 12 and supports the columns 12b. In the lower frame 12c, when the frame 12 configuring the band saw 10 is arranged so as to straddle the object 50 to be cut, the width direction beam 12c1 is divided in order to avoid contact with the object 50 to be cut. Therefore, the frame 12 is configured to have a gate shape in a front view.

The cutting means 14 is an element for cutting the cut object 50, and has a saw blade 14a, wheels 14b1 and 14b2, and elevating frames 14c1 and 14c2. The saw blade 14a is a saw blade formed endlessly by connecting flexible belt-shaped blades in a tubular shape. By driving the saw blade 14a having such a configuration to rotate, a cutting action can be generated without reciprocating the saw blade 14a.

The wheels 14b1 and 14b2 are elements around which the saw blade 14a formed in an endless shape is wound. By fixing a pair of wheels 14b1 and 14b2 to elevating frames 14c1 and 14c2, which will be described later, and by rotating the saw blade 14a around the fixed wheels 14b1 and 14b2, the saw blade 14a is rotated together with the rotation of the wheels 14b1 and 14b2. Will be able to. One wheel 14b2 of the pair of wheels 14b1 and 14b2 is provided with a drive motor 14d for rotation.

The elevating frames 14c1 and 14c2 are frames that ascend and descend along the columns 12b that form the frame 12, and are elements that play a role of moving the saw blade 14a in the cutting direction (vertically downward direction). A pair of elevating frames 14c1 and 14c2 are provided in the width direction of the frame 12. Each of the elevating frames 14c1 and 14c2 is provided with a slider 14e that engages with a guide rail 12b1 provided on the column 12b.

The feeding means 16 is an element for moving the elevating frames 14c1 and 14c2 along the column 12b. The feeding means 16 according to the embodiment has a feed screw 16a, a lifting slider 16b, and a lifting motor 16c. The feed screw 16a is arranged between the columns 12b arranged in the thickness direction of the frame 12 along the standing direction of the columns 12b. The elevating slider 16b is a slider that engages with the feed screw 16a and moves in the extending direction of the feed screw 16a in accordance with the rotation of the feed screw 16a. In the embodiment, the elevating slider 16b is fixed to the elevating frames 14c1 and 14c2 so that the elevating frame 14c1 moves in accordance with the rotation of the feed screw 16a. The elevating motor 16c is a driving means for rotating the feed screw 16a directly or via a gear.

In the embodiment, the feeding means 16 having such a configuration are provided in pairs. Further, by synchronizing the control of the pair of lifting motors 16c, it is possible to horizontally move the saw blade 14a that is wound around the wheels 14b1 and 14b2 fixed to the pair of lifting frames 14c1 and 14c2. Becomes

[Configuration for operation control]
In the band saw 10 according to the embodiment having such a basic configuration, the cutting means 14 is provided with the chip removing means 18, the frame 12 is provided with the chip box 20, the chip receiving plate 22, and the imaging means 24, and the determining means 26 is provided. The control means 28 is attached.

The chip removing means 18 is an element for brushing off the chips attached to the saw blade 14a. The specific configuration is not limited, but may be, for example, a disk-shaped rotating brush that contacts the saw blade 14a.

The chip removing means 18 may be provided in the vicinity of the wheel 14b2 provided with the drive motor 14d, preferably on the delivery side from the wheel 14b2. In the band saw 10 according to the present embodiment, the suitability of the cutting state is determined and controlled based on the state of the chips generated when the object 50 to be cut is cut. Here, regarding the state of the chips generated when the object 50 is cut, it is desirable to collect the chips in the vicinity of the object 50. However, since the cut object 50 of the band saw 10 has a wide variety of shapes and sizes, it is difficult to collect chips in the vicinity of the cut object 50, and various additional means such as a sensor and power (all are not included). (Shown) is required.

On the other hand, the saw blade 14a drawn in the vicinity of the wheels 14b1 and 14b2 provided with the drive motor 14d is just after the object 50 to be cut is cut, and the chips generated by the cutting may be attached. high. Further, by providing the chip removing means 18 on the delivery side from the wheel 14b2, there is no risk of hindering the cutting of the workpiece 50. In the present embodiment, the guide 18a is provided on the lower half side of the chip removing means 18 to prevent the scraped chips from scattering.

The chip box 20 is an element for collecting the chips scraped off from the saw blade 14a by the chip removing means 18, and is arranged so that the chips flow through a chip receiving plate 22, which will be described in detail later. The position of the chip box 20 is not particularly limited, but may be attached to the lower frame 12c, for example.

The chip receiving plate 22 is an element that receives the chips scraped off from the saw blade 14a by the chip removing means 18 and drops them into the chip box 20. The form of the chip receiving plate 22 is not limited, but a side plate that serves as a guide and a valley-shaped inclined surface toward the center of the plate surface are provided so that the falling chips do not leak outside. It is desirable to do so.

The chip receiving plate 22 is arranged directly below the chip removing means 18 so that the chips removed from the saw blade 14a can be reliably received. Further, the chip receiving plate 22 is arranged so as to have an inclination angle θ from the receiving surface for receiving the chips toward the payout portion for dropping the chips into the chip box 20. The inclination angle θ may be adjusted according to the amount of chips accumulated on the chip receiving plate 22. As an example of determining the inclination angle θ, an angle slightly smaller than the repose angle of the chips may be set. With such a configuration, the chips are slightly accumulated on the chip receiving plate 22 and then flow down into the chip box 20 as appropriate.

The imaging unit 24 is an element for acquiring image data for determining the property of chips. The imaging unit 24 is arranged so as to be able to image the chips collected in the chip receiving plate 22. As described above, with the band saw 10, it is difficult to collect chips in the vicinity of the object 50 to be cut. Therefore, there is no guarantee that the chips dropped on the chip receiving plate 22 are necessarily obtained by the latest cutting. Therefore, by collecting a predetermined amount of chips and determining the cutting state based on the property ratio of the chips accumulated during the period, it is possible to improve the accuracy of the determination of the current operating state.

The determining unit 26 is an element for determining the property of the chips based on the image data acquired via the image capturing unit 24 and determining the cutting state. In the present embodiment, chips are classified into four types based on the technical data (see FIG. 4) of the saw blade manufacturer (Starret), and the cutting state (operating state) is determined from the chip type ratio included in the image data. Is determined.

Classification of chips based on image data is performed based on Chip Formation (chip shape) and Chip Color (chip color) in FIG. In the present embodiment, the types of chips shown in FIG. 4 are defined as type 1 to type 4 from the upper side to the lower side in the drawing. The types of chips from type 1 to type 4 are as shown in Chip Condition (chip state) and Chip Color. That is, the type 1 chips are characterized by being Silver (silver) in a state of Thin and Titty Curled (thinly curled). Further, the type 2 chips are characterized by being Powdered and being Silver. Further, the type 3 chips are characterized by being in a Tick and Short state (thick and short) and being Blue or Brown (blue or brown). Further, the type 4 chips are characterized by being Silver in the state of Thin and Curly. Here, the difference between the type 1 chips and the type 4 chips is difficult to judge only by looking at the curled state in a plan view, but the type 1 chips cause a relatively planar curl, whereas The chips have a difference in that they cause elongation in the height direction, and discrimination based on image data is also possible.

In the band saw 10 according to this embodiment, the chip image database 26a storing the teacher data selected for each type is constructed in the storage unit of the determination unit 26. The sample of the teacher data for constructing the chip image database 26a is recorded in several hundreds to several thousands for each chip type, and the teacher data can be increased each time the cutting work is repeated, and the determination accuracy is improved. be able to.

[Judgment procedure]
The determining means 26 can perform the following procedure, for example. First, individual chips contained in the image of the specific range are cut out from the image data acquired by the image pickup means 24. The color or shape characteristics of the chips contained in the cut out image data are acquired to roughly classify the chip types. For example, if the color of the chips is blue or brown other than silver, it can be determined that the chips are likely to be type 3 chips. Further, when the shape of the chips is fine and does not reach the predetermined area, it can be determined that the chips are highly likely to be type 2 chips. Then, it can be determined that the determined chips other than the type 2 and type 3 chips are highly likely to be the type 1 or type 4 chips.

After the rough classification is completed, a detailed determination is performed to compare each type or type 1 and type 4 that are difficult to determine with the teacher data. The comparison determination may be based on a general algorithm for determining the degree of approximation of image data. Based on this algorithm, if the degree of approximation is above a certain level, it can be determined that the chips belong to that type. As described above, by performing the detailed determination after performing the rough division, it is possible to reduce the load of the determination process and shorten the time.

After the type classification is specified by making a detailed determination for each of the chip images cut out from the image data, the ratio of each type of chips included in the image data is obtained, and the operation control pattern of the band saw 10 is determined. .. As a control pattern, as shown in FIG. 4, it is a control pattern for adjusting switching or maintaining of Blade Speed (saw blade speed) and Blade Feed (saw blade feed).

Specifically, when the determination type is type 1, the saw blade speed is Correct, but regarding the saw blade feed, the control pattern is Decrease. If the determination type is type 2, the control pattern is such that the saw blade speed is reduced and the saw blade feed is increased. If the determination type is type 3, the control pattern is such that both the saw blade speed and the saw blade feed are reduced. Furthermore, when the determination type is type 4, both the saw blade speed and the saw blade feed are appropriate, and a control pattern of maintaining the current state is adopted.

The determination result by the determination means 26 is output to the control means 28. The control means 28 outputs a control signal to the drive motor 14d, the lifting motor 16c, or both according to the control pattern input as the determination result. The saw blade speed or saw blade feed according to the control pattern may be changed by increasing or decreasing it by a predetermined ratio (for example, 10%) with respect to the current situation. Further, in performing the determination and control as described above, the initial setting value of the saw blade speed may be the rated speed of the band saw 10.

Here, the saw blade speed and the increase/decrease rate of the saw blade feed determined by the control unit 28 may be changed according to the rate of the type of chips included in the image data. For example, when it is determined that the ratio of type 1 chips is 9 and the ratio of type 4 chips is 1, the rate of change in saw blade feed rate (decrease) may be 10%. On the other hand, when it is determined that the ratio of the type 1 chips is 6, the ratio of the type 4 chips is 3, and the other types are 1, the change ratio of the saw blade feed is set to 5%. To do so. That is, when the content ratio of the type 4 chips is relatively high compared to the content ratio of the type 1 to type 3 chips, control is performed to reduce the change rate of the saw blade speed or the saw blade feed. good.

In this way, by adjusting the change rate by the control pattern according to the content rate of the chip type contained in the image data, it is possible to shorten the convergence time for the adjustment to the proper cutting state.

According to the band saw 10 according to the present embodiment that enables the above-described operation control, the work of cutting the object 50 to be cut under suitable conditions without the know-how of mechanical cutting that a skilled person has gained from a wealth of experience. Will be possible. Therefore, even an unskilled person can carry out the cutting work by the band saw 10. In the present embodiment, "suitable conditions" refer to well-balanced operating conditions in consideration of both prolonging the life of the saw blade and improving cutting efficiency, and may not necessarily be optimal conditions. ..

10... Band saw, 12... Frame, 12a... Upper frame, 12a1... Width beam, 12a2... Thickness beam, 12b... Strut, 12b11... Guide rail, 12c... ......Lower frame, 12c1 ......Width beam, 14 ......Cutting means, 14a .........Saw blades, 14b1, 14b2 ......Wheels, 14c1, 14c2 ...... Lifting frame, 14d ......Drive motor , 14e.........Slider, 16... Feeding means, 16a... Feed screw, 16b... Lifting slider, 16c... Lifting motor, 18... Chip removing means, 18a... Guide, 20.........Chip box, 22.........Chip receiving plate, 24.........Imaging means, 26.........Decision means, 26a.........Chip image database, 28.........Control means, 50... Stuff.

Claims (3)

An endless saw blade, a pair of wheels around which the saw blade is wound, a cutting means having a rotation motor connected to one of the wheels and driven to rotate, and a feeding means for moving the cutting means in a cutting direction. In a band saw equipped with
Chip removing means for removing chips attached to the saw blade,
A chip receiving plate that is disposed below the chip removing means and receives the chips that have fallen and flows to the downstream side,
An image pickup means for picking up an image of the chips accumulated in the chip receiving plate;
Comparing the chips included in the image data captured by the image capturing unit with the teacher data, dividing the chips included in the image data into a plurality of types, and determining unit selecting the type having the highest content ratio;
A band saw comprising: a control unit that controls at least one of a rotation speed of the cutting unit and a feed speed of the feeding unit based on the type selected by the determining unit. The band saw according to claim 1, wherein the type of the chips is determined based on the shape and color of the chips. The control means changes the rate of change of the rotation speed or the feed rate according to the content ratio of the type of the chips contained in the image data determined by the determination means. The band saw according to 1 or 2.