Method for manufacturing orthohexagonal blank of graphite head

Abstract

The invention provides a graphite head regular hexagon blank manufacturing method which comprises the following steps: taking a rectangular carbon brick, and establishing a rectangular coordinate reference system by taking an orthographic projection rectangle of the rectangular carbon brick as a reference and an original point of a point position where a first side is intersected with a second side; obtaining the length of the first side and the length of the second side of the rectangular carbon brick; the preset single bodies are regular hexagonal prisms, are arranged on a first side in a shoulder insertion manner and are arranged in a side-sharing side-by-side manner in the direction of a second side; the cutting line carries out displacement cutting in the first side direction and the side length direction of a preset regular hexagon; according to the scheme, the cutting line walks in the linear direction of the side length of the regular hexagon, three sides of each regular hexagon can be obtained through cutting after each cutter is completed, although each regular hexagon needs to be machined through two cutters, four regular hexagons can be machined through each cutter except for the first cutter, the machining efficiency is high, and the machining cost is low. And the average monomer processing time is short.

Description

Technical Field

[0001] This invention relates to the field of graphite materials for solar energy, and in particular to a method for manufacturing a graphite head hexagonal blank. Background Technology

[0002] Polycrystalline silicon is the main raw material used to produce semiconductors and solar photovoltaic products. Currently, the main methods for producing polycrystalline silicon include the modified Siemens process, the silane process, and the fluidized bed process. Among them, the modified Siemens process and the silane process both require the deposition of a support during the reduction process. The support widely used in the modified Siemens process is silicon core, including square silicon cores and round silicon cores.

[0003] The component used to hold silicon cores in the polysilicon production process is called a graphite head, and its structure is similar to... Figure 8 As shown, or other cylindrical structures, the current processing of this card holder involves first cutting rectangular carbon bricks into cuboid columnar materials, and then machining and drilling them into the required graphite heads. Since the graphite head is a rotating body, the cuboid columnar material 20 first needs to be machined into a cylindrical material, and then precision machined and drilled to obtain the graphite head. This method has the problem of a large amount of raw material being wasted, resulting in low raw material utilization. It is a relatively traditional processing method.

[0004] Another method, such as patent number 2023114881649, involves directly sawing rectangular carbon bricks into cylindrical pieces, which saves raw materials compared to cuboid blanks. However, this method requires processing the carbon bricks into individual cylindrical units, and when using wire cutting, each cylinder is processed separately, requiring individual center point location, which delays processing time and increases positioning errors, affecting processing accuracy. Figure 7 .

[0005] During processing with this technology, each cylindrical unit needs to be processed with a single cut. Furthermore, when cutting cylinders, the cutting line travels slowly, the path is long, the processing efficiency is low, and the lifespan of the cutting line is also short. Summary of the Invention

[0006] In view of the above defects, the present invention proposes a method for manufacturing a graphite head hexagonal blank, comprising the following steps: S10. Take a rectangular carbon brick, and take the orthographic projection rectangle of the rectangular carbon brick as the reference. The orthographic projection rectangle has a first side (110) and a second side (120) that intersect perpendicularly. Take the point where the first side (110) and the second side (120) intersect as the origin, and take the first side (110) as the X-axis and the second side (120) as the Y-axis to establish a rectangular coordinate reference system. S20. Obtain the length of the first side (110) and the second side (120) of the rectangular carbon brick; S30. The preset unit is a regular hexagonal prism, and the orthographic projection is a regular hexagon. It is arranged in a shoulder manner on the first side (110) and in a side-by-side manner on the second side (120). S40. Obtain the individual unit size a according to the process requirements. The individual unit size a is the length of the opposite side of a regular hexagon. Calculate the number of individual units in the first side (110) direction and the number of individual units in the second side (120) direction. S50. The cutting line moves along the first side (110) in the direction of the side length of the preset regular hexagon to cut.

[0007] In this scheme, the cutting line travels along the straight line of the side length of the regular hexagon. After each cut, three sides of each regular hexagon can be cut. Although each regular hexagon requires two cuts to process, except for the first cut, each subsequent cut can process four regular hexagons. The processing efficiency is high and the average processing time per unit is short.

[0008] Compared to the original cylindrical processing method, it has the advantages of high efficiency and safety, and the service life of the cutting line is significantly extended. Compared to the original cube processing method, it has the advantage of saving materials. Attached Figure Description

[0009] Figure 1 This is a schematic diagram of a charcoal brick.

[0010] Figure 2 for Figure 1 Top view.

[0011] Figure 3 This is a partial schematic diagram showing two adjacent units arranged side by side with a shared edge.

[0012] Figure 4 This is a partial schematic diagram of two adjacent single units arranged in a shoulder-like manner.

[0013] Figure 5 This is a schematic diagram of a single unit. The length of opposite sides is 42mm, and the side length is 24.25mm.

[0014] Figure 6 Figure 2 The image shows an explosion diagram illustrating the separation of the first four cuts along the cutting line.

[0015] Figure 7 This is a patent illustration from the background art.

[0016] Figure 8 A schematic diagram of a component that holds a silicon core using existing technology, called a graphite head.

[0017] In the diagram: 100 carbon bricks, 110 for the first side, 120 for the second side, and 200 for the single unit. Detailed Implementation

[0018] The present invention proposes a method for manufacturing a regular hexagonal graphite head blank, comprising the following steps: S10. Take a rectangular carbon brick 100, and take the orthographic projection rectangle of the rectangular carbon brick as a reference. The orthographic projection rectangle has a first side 110 and a second side 120 that intersect perpendicularly. Take the point where the first side 110 and the second side 120 intersect as the origin, take the first side 110 as the X-axis, and take the second side 120 as the Y-axis to establish a rectangular coordinate reference system. S20. Obtain the length of the first side 110 and the second side 120 of the rectangular carbon brick; S30. The preset unit 200 is a regular hexagonal prism, with its orthographic projection being a regular hexagon. It is arranged in a shoulder-like manner along the first side 110, and in a side-by-side manner along the second side 120. This step differs significantly from existing technologies. The arrangement of the regular hexagons in this step is designed to match the direction of the subsequent cutting line positioning. If the carbon block is rotated 90° clockwise or counterclockwise without changing the hexagonal arrangement, the direction of the subsequent cutting line positioning must also be rotated synchronously to ensure that the cutting line moves along the first side 110.

[0019] S40. Obtain the individual unit size a according to the process requirements. The individual unit size a is the length of opposite sides of a regular hexagon. Calculate the number of individual units in the first side 110 direction and the number of individual units in the second side 120 direction. S50. The cutting line moves along the first side 110 in the direction of the preset side length of the regular hexagon to cut.

[0020] In this design, the cutting line travels along the straight line of the hexagon's side length. Each cut yields three sides of each hexagon. Although each hexagon requires two cuts, each subsequent cut produces four hexagons, resulting in high processing efficiency and a short average processing time per unit. Furthermore, the cutting line travels along a straight line, encountering resistance only in the direction perpendicular to its direction of travel. Unlike the resistance encountered in the arc direction during cylinder processing, the side surface formed by this invention is a precise plane, resulting in high processing accuracy.

[0021] Furthermore, in step S50, each cut is made along the first side 110 from left to right.

[0022] like Figure 1-5In this embodiment, the rectangular carbon brick has a second side of 120 = 620 mm and a first side of 110 = 320 mm. During cutting, the cutting line follows the side length of the regular hexagon. Except for the first cut which does not form a single unit, each cut from the second cut onwards can form four units. The cutting line path for the first cut is as follows: Figure 6 The second cutting line is positioned as follows: Figure 6 Then, the process is executed in this order. Although the positions of two adjacent cuts are slightly different, the overall movement path is the same, consisting of four three-sided lengths plus one single-sided length. The time taken to return to the leftmost end and reposition the second cut after each cut is approximately 2 seconds. The second cut still moves from left to right.

[0023] As is well known in the art, the linear travel speed of the cutting wire is 150 mm / min = 2.5 mm / s. Graphite wire cutting uses diamond wire, which is a consumable material, and the lifespan of each diamond wire is fixed. The path traveled when cutting graphite material directly affects its lifespan.

[0024] In this design, the path traveled by each cutter under load (the state of the cutting line cutting the carbon block is the load; the dotted line indicates the non-load state of the cutting line, which does not affect the travel distance or the cutting line life) is 4*(3*24.24)+1*24.24=315.12mm, where 24.24mm is the side length of the regular hexagon. 112 cutters are processed. Figure 6 The layout consists of 14 rows, with each row requiring two cuts to complete. The total path distance is 315.12 * 14 * 2 = 8823.36 mm.

[0025] The total time consumed is 8823.36 / 2.5 + 2 (2s for one side length indicated by the dotted line) * 4 * 28 (cuts) + 2 * 27 (time consumed for switching positions between the two cutters) = 3807.79s. The average processing time for each individual unit is 3807.79 / 112 = 33.99s. Allowing 2s for one side length indicated by the dotted line, the total processing time for 112 individual units is 33.99 / 112 = 0.3s.

[0026] In the background technology of cylindrical machining methods, the machining distance of each cylinder is 131.88mm of circumference, and the machining time is 131.88 / 2.5=52.75s. After machining each cylinder, the center of the next cylinder needs to be repositioned, which takes about 2s. Therefore, after machining 112 cylinders, the path traveled by the cutting line is 131.88*112=14770.56mm, and the time consumed is 52.75*112+2*111=6130s. The average machining time per cylinder is 52.75s.

[0027] Furthermore, in this invention, the cutting line travels in a straight line, and the resistance of the carbon brick to the cutting line is linear. However, when processing a cylinder, the cutting line travels in an arc shape, similar to the path of a rotating body, resulting in greater resistance on the cutting line. Moreover, this resistance is not perpendicular to the cutting line. If the cutting line travels at a high speed, the side of the cylinder formed by the cutting will have a larger outer diameter in the middle than the outer diameters of the top and bottom, similar to a structure with a large belly in the middle. Therefore, the above comparison was made under the premise of the same travel speed. In fact, the cutting line speed for processing cylinders can only reach 50 mm / min.

[0028] The above comparison is made under the premise of ignoring the error in the outer circle of the cylinder caused by the high speed of the cylinder cutting line. Even so, the processing speed of this solution is far superior to that of the original technology for cylinder processing. Of course, regardless of whether the processing is done by the original technology or the present invention, the thickness of the carbon brick is consistent, that is, the unit area of ​​the cutting line is the same.

[0029] The above calculations and comparisons show that, according to the hexagonal arrangement and cutting line positioning method of this scheme, when processing the same number of 112 units, the cutting line travel path is reduced by 14770.56mm - 8823.36mm = 5947.2mm, a reduction of approximately 40% (5947.2 / 14770.56 = 40%). This leads to a 40% reduction in cutting line wear and a 40% extension of service life, demonstrating significant effectiveness. Using the hexagonal arrangement and cutting line positioning method of this scheme, processing the same number of 112 units takes 6130s - 3807.79s = 2322.21s, saving 37.88% of the time (2322.21 / 6130), significantly improving processing efficiency. The average processing time per unit also decreases from 52.75s to 33.99s.

[0030] Furthermore, in step S50, adjacent cuts are connected end-to-end. In the original design, each cut travels along the first side 110 from left to right. Therefore, after one cut, the cutting line needs to return from the rightmost end to the leftmost end, and the reset and repositioning time is about 2 seconds. Accumulated, this time consumption is not negligible. In mass production, controlling every detail and saving time can bring beneficial effects. With this improved solution, the first cut travels from left to right. Since each cut forms three sides of a regular hexagon, the rightmost end after the first cut is exactly the starting point of the second cut. Therefore, the cutting line does not need to return to the leftmost end, thus eliminating the 2-second reset and repositioning time, further saving time. The time consumed by this solution to process 112 units is 3807.79 - 2 * 27 = 3753.79 seconds, saving 2 * 27 = 54 seconds compared to the original solution. Figure 2 , 6 As shown.

[0031] The embodiments of this solution have been described in detail above with reference to the accompanying drawings. However, this solution is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this patent.

Claims

1. A method for manufacturing a graphite head hexagonal blank, characterized in that... Includes the following steps: S10. Take a rectangular carbon brick, and take the orthographic projection rectangle of the rectangular carbon brick as the reference. The orthographic projection rectangle has a first side (110) and a second side (120) that intersect perpendicularly. Take the point where the first side (110) and the second side (120) intersect as the origin, and take the first side (110) as the X-axis and the second side (120) as the Y-axis to establish a rectangular coordinate reference system. S20. Obtain the length of the first side (110) and the second side (120) of the rectangular carbon brick; S30. The preset unit is a regular hexagonal prism, and the orthographic projection is a regular hexagon. It is arranged in a shoulder manner on the first side (110) and in a side-by-side manner on the second side (120). S40. Obtain the individual unit size a according to the process requirements. The individual unit size a is the length of the opposite side of a regular hexagon. Calculate the number of individual units in the first side (110) direction and the number of individual units in the second side (120) direction. S50. The cutting line moves along the first side (110) in the direction of the side length of the preset regular hexagon to cut.

2. The method for manufacturing a graphite head hexagonal blank as described in claim 1, characterized in that... In step S50, each cut is made along the direction of the first side (110) from the left end to the right end.

3. The method for manufacturing a graphite head hexagonal blank as described in claim 1, characterized in that... In step S50, two adjacent cuts are joined end to end.

4. The method for manufacturing a graphite head hexagonal blank as described in claim 1, characterized in that: During the cutting line processing, one side length between two three-sided lengths does not need to be cut by the cutting line. By adjusting the speed of the cutting line, the time required for the cutting line to travel to that side length is shortened.

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