RU72434U1 - UNIVERSAL TECHNOLOGICAL COMPLEX FOR THE PRODUCTION OF CUTTING DISKS OF A LARGE DIAMETER WITH LASER CUTTING AND BALANCING - Google Patents

Abstract

The universal technological complex for the production of large diameter cutting discs with laser cutting and balancing contains at least two working tables: a fixed cutting table (1) and a balancing table (2), as well as a bridge-type laser cutting machine, the laser cutting head (3) of which it is located on the horizontal part of the bridge (4) with the possibility of moving the laser cutting head (3) on it above the cutting table (1) or above the balancing table (2). Vertical supports (5, 6) of the bridge (4) are mounted on rails (7, 8) with the possibility of moving the bridge (4) with the laser laser cutting machine above the table (1) or above the balancing table (2) or from the table (1) cutting to the table (2) balancing. The complex is equipped with a control computer (9) that controls the cutting process (UVM), and a computer (19) for balancing (PVEM) and a microprocessor controller (10). The balancing table (2) is equipped with a rotation angle sensor (11) connected to the indicated controller (10) and, for example, four weight strain gauges (12) with an accuracy of at least 0.01% of the disk weight (13), as well as connected to a computer ( 19) a drive (14) with an electric motor (15) kinematically connected by a belt drive (16) mounted on a table (2) in a glass (18) and supported on a thrust spherical roller bearing (17) [with a cone-shaped roller with a slightly pronounced spherical shape at an angle of 45 degrees from the horizontal] and a fixed radial ball with a co-bearing (20), a landing unit (21) for installing a balanced disk (13). The angle sensor (11) can be mounted on an electric motor (15). The complex allows you to use one of the tables to balance the disk after it is cut from the workpiece, and to remove excess metal during balancing, use the laser cutting machine with which the disk was made to form the task of the laser cutting machine to remove excess metal according to calculations based on weight measurements drive in several radial directions in a stationary position and during rotation. At the same time, the best product quality is achieved (high service life and low risk of disk failure, the service life of metal cutting saws is extended), since there are no deformations and residual stresses of the metal inherent in tooth cutting by milling. The complex allows you to carry out the balancing process iteratively, until the desired accuracy is achieved.

Description

The utility model relates to the field of production of cutting tools from sheet steel billets obtained on a rolling mill, in particular large diameter cutting discs (from 2000 to 3000 mm), which are used in hot and cold cutting of metal, the quality of which substantially depends on the quality of their balancing .

Technological complexes for the production of cutting discs RU1013075, RU 1199341, RU 1581443, RU 2127174, US 6634186 are known from the patent literature.

The disadvantages of these devices are low productivity, low precision manufacturing of the cutting part due to deformation and residual stresses of the metal, lack of balancing, which reduces the efficiency of use of the cutting tool and its durability, high labor intensity and the duration of the manufacturing cycle.

Technological balancing complexes RU 171621, RU 567984, RU 1244521, RU 1787268, US 4945763, US 6342030, US6493311, US 6778353, US 7008360, US 7020950, US 7099112 are known from the patent literature.

The disadvantages of these devices are the lack of quickly available data on the balancing parameters, low accuracy of determining the places of removal of excess material due to the large influence of the human factor on the accuracy and quality of balancing, as well as high labor costs, the inability to accumulate, store and use statistical information.

The technical task of the utility model is the creation of an effective fully automated technological complex for the production of cutting discs and the expansion of the arsenal of technological complexes for the production of cutting discs.

The technical result, which provides a solution to the problem, is to ensure the versatility of the complex for sequentially performing one cutting means (laser cutting machine) of disk shaping without deformation and residual metal stresses and subsequent balancing of the product, reducing the finished manufacturing time

disk due to minimal transportation and quick calculation of balancing parameters, increasing the accuracy of determining the places of removal of excess material and reducing labor costs when cutting and balancing, ensuring the accumulation, storage and operational use of statistical information.

The essence of the utility model lies in the fact that the technological complex for the production of cutting disks contains a cutting table and a balancing table, as well as a bridge-type laser cutting machine, the laser cutting head of which is located on the horizontal part of the bridge with the possibility of moving the laser cutting head above or above the cutting table the balancing table, and the vertical bridge supports are mounted on rails with the ability to move the bridge with the laser cutting machine from the cutting table to the balancing table, the complex also contains controls an effective cutting computer, a balancing computer, and a microprocessor controller, wherein the balancing table is equipped with a rotation angle sensor and weight load cells connected to the specified controller with an accuracy of at least 0.01% of the disk weight, as well as a drive with an electric motor connected through the microprocessor controller to the balancing computer kinematically connected to a thrust bearing supported on a table-mounted landing unit for installing a balancing disk.

In preferred particular cases of implementation, the balancing table is equipped with from 4 to 6 weight load cells uniformly distributed around the circumference around the disk, the microprocessor controller is configured to determine the radius vector of the disk with the largest weight, the complex is equipped with a crane beam, and the latter is equipped with magnetic or vacuum grippers, and the rails are equipped with gear racks, and the balancing computer is capable of reading data from a microprocessor controller, determining excess weight for radius vectors emanating from the center of the disk to the load cells when measuring the weight of the disk by radius vectors in a stationary state and during rotation, presenting the balancing results in the form of pie charts and graphs of the dependence of the weight of the disk on radius vectors on the rotation angle, as well as the formation and transferring the cutting control program to remove excess metal during balancing on the balancing table to the cutting control computer.

The drawing of Fig. 1 shows a general diagram of a universal technological complex for the production of large diameter cutting discs with laser cutting and balancing, in Fig. 2 - a disk on a balancing table, in Fig. 3 - a diagram of a balancing assembly, in Fig. 4 - a layout of weighted load cells around the circumference of the disk, Fig. 5 is an example of a pie chart illustrating the determination of the radius vector of an unbalanced weight when the disk is stationary; Fig. 6 is a pie diagram similar to Fig. 5 during rotation of the disk.

The universal technological complex for the production of large diameter cutting discs with laser cutting and balancing contains at least two working tables: a fixed cutting table (1) and a balancing table (2), as well as a bridge-type laser cutting machine, the laser cutting head (3) of which it is located on the horizontal part of the bridge (4) with the possibility of moving the laser cutting head (3) on it above the cutting table (1) or above the balancing table (2). Vertical supports (5, 6) of the bridge (4) are mounted on rails (7, 8) with the possibility of moving the bridge (4) with the laser laser cutting machine above the table (1) or above the balancing table (2) or from the table (1) cutting to the table (2) balancing. The complex is equipped with a control computer (9) that controls the cutting process (UVM), and a computer (19) for balancing (PVEM) and a microprocessor controller (10). The balancing table (2) is equipped with a rotation angle sensor (11) connected to the indicated controller (10) and, for example, four weight strain gauges (12) with an accuracy of at least 0.01% of the disk weight (13), as well as connected to a computer ( 19) a drive (14) with an electric motor (15) kinematically connected by a belt drive (16) mounted on a table (2) in a glass (18) and supported on a thrust spherical roller bearing (17) [with a cone-shaped roller with a slightly pronounced spherical shape at an angle of 45 degrees from the horizontal] and a fixed radial ball with a co-bearing (20), a landing unit (21) for installing a balanced disk (13). The angle sensor (11) can be mounted on an electric motor (15).

The balancing table (2) can be equipped with up to six weight strain gauges (12), evenly distributed around the circumference around the disk (13).

The complex is equipped with a crane beam (not shown), and the latter is equipped with magnetic or vacuum grippers (not shown), and the rails (7.8) are equipped with gear racks (not marked).

The computing machine (19) is made in the form of a PVEM with the possibility of rotating the disk (13) on the balancing table (2), determining the excess weight for the radius vectors coming from the center of the disk (13) to the load cells (12) when measuring the weight of the disk (13) ) on radius vectors in a stationary state and during rotation, as well as presenting the balancing results in the form of pie charts and graphs of the dependence of the disk weight by radius vectors on the rotation angle.

The set of a laser cutting machine includes a cabinet with electronic equipment, which contains, among other things, the mentioned cutting control computer (9), which runs the cutting program. This is a specialized computing machine, which differs in its characteristics from a PC (19). It is not practical to use it for balancing, since the software and hardware implementation of UVM do not allow simultaneous execution of cutting and balancing work on tables (1, 2). PC and UVM are combined into a local network (not shown).

The universal technological complex for the production of large diameter cutting blades with laser cutting and balancing is operated as follows.

Large diameter cutting discs (from 2000 mm to 3000 mm, hereinafter referred to as “disks”) are used in saws for hot and cold metal cutting. They are made from sheet steel billets obtained on a rolling mill. For example, a disk with a diameter of 2500 mm is cut from a square billet of 2550x2550 mm, 12 mm thick, weighing about 450 kg. When using any method of manufacturing disks (13), due to the irregularities of the steel sheet of the billet obtained at the rolling mill, subsequent balancing is necessary. The task is to ensure that the disc weight (13) deviates over four radii (in increments of 90 degrees) of no more than 1/1000 of the total weight of the disc (13). This determines the choice of weight strain gauges (12) with an accuracy of at least 0.01% of the weight of the disk (13).

Since the dimensions of the workpieces are very large and the material has a large thickness, a necessary condition is the provision of a large working space, which is ensured by the bridge arrangement of the cutting head (3) of the laser, as well as high laser power (for gas - from 2500 W). At

high laser power it is possible to obtain high quality processing of the edges of the teeth of the disk (13), comparable with that obtained during milling. In the bridge-type laser cutting machine, fixed work tables (1, 2) are used, and the laser cutting head (3) is located on the horizontal part of the bridge (4) and moves horizontally perpendicular to the direction of the rails (7, 8) along which the vertical supports (5 , 6). At the same time, the gear drive of the drive (not shown) “clings” to the rail rails of the rails (7, 8), which accurately positions the complex when moving along the rails (7, 8).

The sequence of movements when performing technological operations for the manufacture of a disc with balancing is as follows.

The bridge (4) moves to a safe position at the table (1), in which if the disk (13) (or its workpiece) was moved using a crane beam (not shown), it was impossible to touch the bridge (4) with a laser or something drop it on him. A workpiece is installed on the table (1). The bridge (4) moves to the table (1). The laser cutting machine starts up and cuts the disk (13) on the table (1). The cutting process in automatic mode is controlled by the UVM (9). On the table (2), calibration operations of the measuring system (10, 19) are performed. After cutting is completed on the table (1), the bridge (4) moves to a safe position.

The disk (13) moves from the table (1) to the table (2). The following workpiece is installed on the table (1). The bridge (4) moves to the table (1). The laser cutting machine starts up and cuts the next disk (13) on the table (1). On the table (2), the measurement operations of balancing the first disk (13) are performed.

The bridge (4) moves to the table (2).

Information on the performance of the cutting operation (removal of excess metal necessary for balancing) on the table (2) in the form of codes of the cutting program generated on the PC (19) is transmitted via the network to the computer (9).

On the table (2), cutting operations are carried out (removal of excess metal necessary for balancing). After completion of these balancing operations on the table (2), the measuring balancing operations are repeated. If necessary, cutting operations are repeated (removal of excess metal necessary for balancing), otherwise:

The bridge (4) moves to a safe position.

The finished disk (13) is removed from the table (2).

Further, the above operations are repeated.

The sequence of operations performed on the balancing device.

Before the start of technological operations, the measurement system is calibrated without an installed disk (13) on the table (2), during which the following steps are performed. Using weight strain gauges (12) using a microprocessor controller (10), the initial weight corresponding to each strain gauge (12) is determined. The angle of rotation sensor (11), using the controller (10), determines the initial angle of rotation. A PC (19) receives data from the controller (10) and stores them as initial data for subsequent calculations.

Measuring balancing operations after installing the disk (13) on the table (2) are performed as follows.

Using the load cells (12) with the help of the controller (10), the weight corresponding to each load cell (12) is determined. Further, the measurements are repeated after changing the position of the disk (13), its rotation is performed by an electric motor (15) by an angle equal to 360 degrees divided by the number of tanzosensors (12). The number of measurements and rotations of the disk (13) is determined by the requirements of a given balancing accuracy, the best results will be given by an average measurement for each load cell (12) for 60 ms with a speed of at least 5000 measurements per second (for the best quality filtering of noise from a supply sinusoidal voltage of 50 Hz) when turning to the load cell (12) from 5 to 10 times. The measurement process is controlled by a PC (19) that reads data from the controller (10) and controls the drive (14). The disk balancing data in a stationary state is stored on a PC (19) and presented in the form of a pie chart.

In this case, a personal computer (19) determines the excess weight for radius vectors originating from the center of the disk (13), the number of which is equal to the number of load cells (12).

After the above measurements, when the disk is stationary, the disk (13) is rotated on the landing unit (21) by an electric motor (15) with a given set of speeds depending on the weight of the disk (13), up to 60 rpm in increments of 10 rpm. When the disk rotates, the controller (10) performs measurement operations in parallel for each load cell (12) (average over 20 ms at a speed not

below 5000 measurements per second, for filtering interference) and to the sensor (11), the data obtained are stored on a personal computer (19) and graphically presented in the form of a set of graphs in coordinates (weight on a strain gauge (12), rotation angle) and in the form of pie charts for whole set of speeds.

Figure 5 illustrates an example of the presence of an imbalance in the weight of the disk (13) between adjacent load cells (12). The axes denote the values of w1, w2, w3 and w4, corresponding to the average values of the measured unbalance of weight for four load cells (12) in the range from the difference between the average and minimum measured to the difference between the maximum measured for all load cells (12). The angle a of the radius vector R emanating from the center indicates the radius vector of the disk (13) with maximum unbalance.

When the disk (13) rotates due to a displaced axis of rotation in the presence of irregularities with an increase in the number of revolutions n, the average values of the weight unbalance increase, as shown in Fig.6. The metal removal point for eliminating unevenness is located on the radius vector R with the average value of the angle a. The larger the distance of the point from the center of the disk (13), the greater its contribution to the values of w1 and w2, proportional to the distance of the unbalance point from the center. The weight of the metal to be removed is approximately the square root of the sum of the squares of the difference w1 and w3 and the difference w2 and w4.

On a PC (19), from the above measurement results, the point (or points) of unbalance is determined on the radius vectors with excess weight determined as a result of the calculations.

Points can be defined in the area of cutting teeth or close to the mounting hole of the disk (13), in which case the point is moved closer to the center or further from the center of the disk (13), respectively, but without going beyond the range of 1/3 to 3/4 of the radius disk (13). In the most typical case, the location of the metal removal points is determined by the technological requirements for the manufacture of the disk (13): they should be located at the same distance from the center, previously agreed upon by the Technical Specifications for the product, and then the weight of the removed metal is calculated based on these conditions.

A personal computer (19) presents the resulting data to the operator in a visual form for manually setting up a laser cutting machine for cutting (metal removal at unbalance points), as well as control codes of the laser cutting machine program for performing operations in a semi-automatic mode for a computer (9). results

measurements are not only presented in graphical form for perception by the operator, but the operator also receives, as a result of calculations on a computer (19), the coordinates of the disk points (13) with irregularities and instructions for removing excess metal at the calculation points that are used to perform cutting operations when removing unevenness.

Cutting operations (metal removal) during balancing are performed as follows.

The operator sets the disk (13) to a previously defined starting position on the table (2), using data from the sensor (11). The bridge (4) moves to the table (2). Operations are performed to cut holes of the calculated diameter at the identified design points of unevenness, or to remove a given upper layer of metal in a technologically determined area (the choice of operation is determined by the technological requirements of the Customer for the manufacture of disks).

The universal technological complex for the production of large diameter cutting blades with laser cutting and balancing allows you to use one of the tables to balance the disk after cutting it from the workpiece by installing a balancing device on the table, and use a laser cutting machine to remove excess metal during balancing, with which it was made disk, form the task of the laser cutting machine to remove excess metal according to calculations based on the results of measuring the weight of the disk over several radial movements in a stationary position and during rotation. The manufacture of disks using a laser cutting machine (hereinafter “MLR”) gives the best product quality (high service life and low risk of destruction of the disk, prolongs the service life of metal cutting saws), since there are no deformations and residual stresses inherent to tooth cutting by milling. The above complex allows balancing iteratively, until the desired accuracy is achieved.

Claims (5)

1. Technological complex for the production of cutting discs, containing a cutting table and a balancing table, as well as a bridge-type laser cutting machine, the laser cutting head of which is located on the horizontal part of the bridge with the possibility of moving the laser cutting head over it above the cutting table or above the balancing table, and vertical the bridge supports are mounted on rails with the possibility of moving the bridge with the laser cutting machine from the cutting table to the balancing table, the complex also contains a control cutting computer, an balancing machine and a microprocessor controller, and the balancing table is equipped with a rotation angle sensor and weight load cells connected to the specified controller with an accuracy of at least 0.01% of the disk weight, as well as a drive with an electric motor kinematically connected to the supported motor connected via a microprocessor controller to the balancing computer on the thrust bearing in a seat mounted on the table for installing a balanced disc. 2. The complex according to claim 1, characterized in that the balancing table is equipped with from 4 to 6 weight strain gauges, evenly distributed around the circumference around the disk. 3. The complex according to any one of claims 1, 2, characterized in that the microprocessor controller is configured to determine the radius vector of the disk with the largest weight. 4. The complex according to any one of claims 1, 2, characterized in that it is equipped with a crane beam, and the latter is equipped with magnetic or vacuum grippers, and the rails are equipped with gear racks. 5. The complex according to any one of claims 1, 2, characterized in that the balancing computer is capable of reading data from the microprocessor controller, determining excess weight for radius vectors coming from the center of the disk to the load cells when measuring disk weight by radius vectors in a stationary state and during rotation, the presentation of the balancing results in the form of pie charts and graphs of the dependence of the disk weight by radius vectors on the rotation angle, as well as the formation and transmission of the control program sharp to remove excess metal when balancing on the table balancing in the control cutting computer.