A circular saw for stone cutting and its control method

Abstract

This invention proposes a circular saw for stone cutting, comprising a main body; the main body includes a cutting mechanism and a supporting mechanism for supporting the cutting mechanism; the supporting mechanism includes a support base and a set of movable wheels located below the support base; the main body also includes a control mechanism; the control mechanism includes a first drive device for driving the movable wheels; the movable wheels include a first wheel set and a second wheel set cooperating with the first wheel set; the first drive device further includes a first drive motor for driving the first wheel set and a second drive motor for driving the second wheel set; the control mechanism further includes a walking frequency converter connected to the first and second drive motors and a controller connected to the walking frequency converter. The controller controls the walking frequency converter, adjusting its output frequency, thereby adjusting the feed rate of the movable wheels to adapt to cutting different hardness areas and improving energy efficiency.

Description

Technical Field

[0001] This invention relates to the field of quarrying machinery technology, specifically to a circular saw for stone cutting and its control method. Background Technology

[0002] When cutting hard materials such as stone from mining, the commonly used cutting devices are cutting tools with ring-shaped blades, such as band saws, chainsaws, wire saws, and circular saws. Circular saws, in particular, have two independently driven circular saw blades that cut the stone synchronously. These dual-circular saws have a traveling structure that drives the saw along a pre-defined track to efficiently cut both sides of the stone. In existing technologies, a fixed traveling speed is set to ensure the circular saw cuts the stone at a uniform speed. However, the hardness of stone varies at different locations. Cutting harder areas requires a slower travel speed, resulting in a longer cutting time for the circular saw. Cutting softer areas allows for a faster travel speed, increasing cutting efficiency. Compared to uniform cutting, adaptively adjusting the travel speed according to the stone's hardness reduces energy waste and improves cutting efficiency.

[0003] In view of this, the inventors of this case conducted in-depth research on the above-mentioned problems, which led to the creation of this case. Summary of the Invention

[0004] The purpose of this invention is to provide a circular saw for stone cutting with adaptively adjustable walking speed, so as to solve the problems in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A circular saw for stone cutting includes a main body; the main body includes a cutting mechanism and a support mechanism for supporting the cutting mechanism; the support mechanism includes a support seat and a set of movable wheels located below the support seat; the main body also includes a control mechanism; the control mechanism includes a first drive device for driving the movable wheels to move; the movable wheels include a first wheel set and a second wheel set cooperating with the first wheel set; the first drive device also includes a first drive motor for driving the first wheel set to rotate and a second drive motor for driving the second wheel set to rotate; the control mechanism also includes a walking frequency converter connected to the first drive motor and the second drive motor and a controller connected to the walking frequency converter.

[0007] The cutting mechanism includes a housing and a saw blade mounting base rotatably connected to the housing for mounting a saw blade; the saw blade mounting base includes a first mounting base and a second mounting base located on both sides of the housing; the control mechanism further includes a third drive motor for driving the first mounting base to rotate and a fourth drive motor for driving the second mounting base to rotate.

[0008] The control mechanism further includes a cutting control component; the cutting control component includes a first frequency converter connected to the third drive motor and a second frequency converter connected to the fourth drive motor.

[0009] The controller is connected to the walking frequency converter, the first frequency converter, and the second frequency converter, respectively.

[0010] The controller includes a touch screen and an intermediate relay.

[0011] The control mechanism also includes a first hydraulic cylinder that drives the first card holder to extend and retract outwards, and a second hydraulic cylinder that drives the second card holder to extend and retract outwards.

[0012] The cutting mechanism also includes a guide rod that is vertically arranged on the support seat; the housing is slidably connected to the guide rod; the control mechanism also includes a third hydraulic cylinder that drives the housing to move up and down along the guide rod.

[0013] The first wheel set includes two first wheel bodies and two second wheel bodies whose rotation direction is perpendicular to the first wheel bodies; the second wheel set includes two third wheel bodies and two fourth wheel bodies whose rotation direction is perpendicular to the third wheel bodies; the second drive device also includes a fourth cylinder, a fifth cylinder, a sixth cylinder and a seventh cylinder disposed at the four corners of the support seat.

[0014] The control mechanism also includes a hydraulic station pump and a main control module for controlling the hydraulic station pump; the hydraulic station pump is connected to the first cylinder, the second cylinder, the third cylinder, the fourth cylinder, the fifth cylinder, the sixth cylinder, and the seventh cylinder respectively.

[0015] A control method for a circular saw for stone cutting includes the following steps.

[0016] s1. Set the preset current value: Set the preset current value A1 and the walking speed D for automatic cutting on the touch screen;

[0017] s2. Obtain the current comparison value: Obtain the actual current values ​​of the first and second frequency converters during the cutting process, compare the two current values, and take the larger value as the current comparison value A2.

[0018] s3. Set the frequency gain value KP and integral action parameter KI of the walking frequency converter driver;

[0019] s4. Comparison Calculation: When the current comparison value is less than the preset current value, the walking frequency converter increases the output frequency by (A1-A2) / A1 multiplied by KP, thereby increasing the walking speed D; when the current comparison value is greater than the preset current value, the walking frequency converter decreases the output frequency by (A2-A1) / A1 multiplied by KP, thereby decreasing the walking speed D.

[0020] After adopting the above technical solution, a circular saw for stone cutting has at least the following beneficial effects:

[0021] In actual implementation, the controller controls the walking drive frequency converter to adjust the output frequency of the walking drive frequency converter, thereby adjusting the feed rate of the moving wheel set to achieve the function of "accelerating when encountering soft and decelerating when encountering hard" to adapt to cutting stone ore bodies of different hardness and improve the efficiency of power utilization. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of a circular saw for stone cutting according to an embodiment of the present invention;

[0023] Figure 2 This is a schematic diagram of the control mechanism of a circular saw for stone cutting according to an embodiment of the present invention;

[0024] In the picture:

[0025] Cutting mechanism 1; bearing mechanism 2; control mechanism 3; moving wheel set 21; housing 11; saw blade mounting base 12; guide rod 22; first wheel body 211; second wheel body 212; third wheel body 213; fourth wheel body 214. Detailed Implementation

[0026] To further explain the technical solution of the present invention, the following is an explanation... Figure 1 The specific embodiments are described in detail below.

[0027] A circular saw for stone cutting includes a main body; the main body includes a cutting mechanism 1 and a supporting mechanism 2 for supporting the cutting mechanism 1; the supporting mechanism 2 includes a support seat and a set of moving wheels 21 located below the support seat; the main body also includes a control mechanism 3; the control mechanism 3 includes a first drive device for driving the moving wheels 21 to move; the moving wheels 21 includes a first wheel set and a second wheel set that cooperates with the first wheel set; the first drive device also includes a first drive motor for driving the first wheel set to rotate and a second drive motor for driving the second wheel set to rotate; the control mechanism 3 also includes a walking frequency converter connected to the first drive motor and the second drive motor and a controller connected to the walking frequency converter. In actual implementation, the controller controls the walking drive frequency converter to adjust the output frequency of the walking drive frequency converter, thereby adjusting the feed rate of the moving wheels 21 to achieve the function of "accelerating when encountering soft material and decelerating when encountering hard material" to adapt to cutting stone ore bodies of different hardness and improve energy utilization efficiency.

[0028] Preferably, the cutting mechanism 1 includes a housing 11 and a saw blade mounting base 12 rotatably connected to the housing 11 for mounting the saw blade; the saw blade mounting base 12 includes a first mounting base and a second mounting base located on both sides of the housing 11; the control mechanism 3 further includes a third drive motor for driving the first mounting base to rotate and a fourth drive motor for driving the second mounting base to rotate. In actual implementation, the first mounting base is driven by the third drive motor, and the second mounting base is driven by the fourth drive motor. By controlling the output power of the third drive motor and the fourth drive motor, the rotational speed of the circular saw can be effectively controlled.

[0029] Preferably, the control mechanism 3 further includes a cutting control component; the cutting control component includes a first frequency converter connected to the third drive motor and a second frequency converter connected to the fourth drive motor. In actual implementation, the speed of the third drive motor is adjusted by controlling the output frequency through the first frequency converter; the speed of the fourth drive motor is adjusted through the second frequency converter; this allows for efficient adjustment of the third and fourth drive motors to adapt to different hardness areas of the stone.

[0030] Preferably, the controller is connected to the walking frequency converter, the first frequency converter, and the second frequency converter, respectively. In actual implementation, the controller controls the walking frequency converter to control the walking speed while simultaneously controlling the first and second frequency converters to control the cutting speed. Specifically, when cutting the high-hardness part of the stone, the controller controls the walking frequency converter to reduce the output power of the first and second drive motors, resulting in a decrease in the walking speed. At the same time, it controls the first and second frequency converters to increase the output power of the third and fourth motors, resulting in an increase in the cutting speed, which can better cut the high-hardness part and improve cutting efficiency. When cutting the low-hardness part of the stone, the controller controls the walking frequency converter to increase the output power of the first and second drive motors, resulting in an increase in the walking speed. At the same time, it controls the first and second frequency converters to reduce the output power of the third and fourth motors, resulting in a lower cutting speed, which can better cut the low-hardness part and improve cutting efficiency.

[0031] Preferably, the controller includes a touch screen and an intermediate relay. In actual implementation, in automatic mode, the touch screen reads and writes the operating data of the walking frequency converter, the first frequency converter, and the second frequency converter via RS485 communication, thereby controlling the frequency converters. The data displayed on the touch screen allows for precise control of the walking speed and cutting speed, thus improving cutting efficiency. In manual mode, the walking speed and cutting rotation can be controlled via the intermediate relay. Manual mode is usually used as a supplement to automatic mode.

[0032] Preferably, the control mechanism 3 further includes a first hydraulic cylinder that drives the first mounting bracket to extend outward and a second hydraulic cylinder that drives the second mounting bracket to extend outward. In actual implementation, the first hydraulic cylinder causes the first mounting bracket to extend outward and the second hydraulic cylinder causes the second mounting bracket to extend outward, thereby adjusting the width of the stone to be cut, making it convenient for the user.

[0033] Preferably, the cutting mechanism 1 further includes a guide rod 22 mounted on a support and arranged vertically; the housing 11 is slidably connected to the guide rod 22; the control mechanism 3 further includes a third hydraulic cylinder that drives the housing 11 to move up and down along the guide rod 22. In actual implementation, the circular saw is lowered by the third hydraulic cylinder, making it easier for the user to cut stones of different thicknesses and facilitating user operation.

[0034] Preferably, the first wheel assembly includes two first wheel bodies 211 and two second wheel bodies 212 whose rotation direction is perpendicular to the first wheel bodies 211; the second wheel assembly includes two third wheel bodies 213 and two fourth wheel bodies 214 whose rotation direction is perpendicular to the third wheel bodies 213; the second drive device further includes a fourth cylinder, a fifth cylinder, a sixth cylinder and a seventh cylinder disposed at the four corners of the support seat. In actual implementation, the first wheel 211 is parallel to the third wheel 213, and the second wheel 212 is parallel to the fourth wheel 214. Specifically, the fourth and fifth hydraulic cylinders are located on both sides of the first wheel group; the sixth and seventh hydraulic cylinders are located on both sides of the second wheel group. When it is necessary to change the travel track, the fourth and fifth hydraulic cylinders extend to lift the first wheel group and insert the first track perpendicular to the travel track. After the track is inserted, the fourth and fifth hydraulic cylinders retract. Then, the sixth and seventh hydraulic cylinders extend to lift the second wheel group and insert the second track in the same direction. Then, the sixth and seventh hydraulic cylinders retract. At this time, the first drive motor drives the second wheel 212 to rotate and move along the first track, and the second drive motor drives the fourth wheel 214 to rotate and move along the second track. This causes the circular saw to move in the direction perpendicular to the travel direction, which facilitates the replacement of the track.

[0035] Preferably, the control mechanism 3 further includes a hydraulic station pump and a main control module for controlling the hydraulic station pump; the hydraulic station pump is connected to the first, second, third, fourth, fifth, sixth, and seventh cylinders respectively. In actual implementation, the main control module controls the hydraulic station pump to supply oil to the first, second, third, fourth, fifth, sixth, and seventh cylinders, enabling each cylinder to operate independently and achieve efficient control.

[0036] A control method for a circular saw for stone cutting includes the following steps.

[0037] s1. Set the preset current value: Set the preset current value A1 and the walking speed D for automatic cutting on the touch screen;

[0038] s2. Obtain the current comparison value: Obtain the actual current values ​​of the first and second frequency converters during the cutting process, compare the two current values, and take the larger value as the current comparison value A2.

[0039] s3. Set the frequency gain value KP and integral action parameter KI of the walking frequency converter driver;

[0040] s4. Comparison Calculation: When the current comparison value is less than the preset current value, the walking frequency converter increases the output frequency by (A1-A2) / A1 multiplied by KP, thereby increasing the walking speed D; when the current comparison value is greater than the preset current value, the walking frequency converter decreases the output frequency by (A2-A1) / A1 multiplied by KP, thereby decreasing the walking speed D.

[0041] In actual implementation, taking a larger value as the current comparison value in step s2 can effectively prevent overload of either the third or fourth drive motor, avoiding motor damage. Specifically, during the cutting process, the actual cutting comparison current value is positively correlated with the cutting load. When the cutting load increases, the comparison current value also increases accordingly. With the travel speed remaining constant, cutting high-hardness parts will increase the cutting load, while cutting low-hardness parts will decrease the cutting load. The motor has three states during operation: no-load, overload, and full-load. Among them, the full-load state has the highest cutting efficiency. From no-load to... During full load operation, the motor's operating current gradually increases. To reduce energy waste, the motor's operating current can be kept within the full load current range during operation. By increasing or decreasing the load, the circular saw can cut efficiently, improving energy efficiency. The preset current value can be set at 80% of the full load current value. In step s4, the walking speed is adjusted by the ratio of the difference between the current comparison value and the preset current value. When the difference is large, the adjustment rate is high; when the difference is small, the adjustment rate is low. This allows the current comparison value to be efficiently adjusted around the preset current value, quickly approaching it and reducing energy waste.

[0042] For example, during the cutting process with a small saw blade, the operating current of the first frequency converter driver A1 is 50A; the operating current of the second frequency converter driver A2 is 60A. The touchscreen calculates and compares A2 > A1, taking A2 as the output current comparison value. A preset current value of 80A is set as the input using the touchscreen. The KP gain value of the small chip in the walking frequency converter driver is set to 0.5, the KI integral value to 3, and the current comparison value 60 < the preset current value 80, with a difference of 20. (That is, the comparison current value < the preset current value, at which point the walking drive mechanism needs to increase its movement speed). At this time, the PID function of the walking frequency converter driver increases the output frequency by multiplying the ratio of the difference to the preset current value by KP each time, causing the walking drive to increase its movement speed. The load on the first and second frequency converter drivers increases, and the current increases accordingly. As the current difference from the preset current value decreases, the amount of proportional adjustment gradually decreases. When the current comparison value approaches the preset current value, in order to balance the current comparison value with the preset current value and maintain a stable cutting state, the integral adjustment function adjusts the function according to the cumulative time of the KI value. A larger KP value results in more proportional adjustment, while a smaller KP value results in faster integral adjustment. Conversely, when the comparison current value exceeds the preset current value, the travel drive mechanism needs to slow down. In this case, the PID function of the travel inverter driver reduces the output frequency by multiplying the difference by KP each time, thus slowing down the travel drive.

[0043] The value range of KP is 0.00-10.00;

[0044] The value range of KI is 0.1-100.0;

[0045] The touchscreen has IoT capabilities, enabling it to collect and statistically analyze on-site cutting data in real time, monitor operational status, and facilitate remote maintenance and control.

[0046] The controller has front and rear limit functions to control and adjust the walking distance, realize automated control, reduce reliance on manual labor, and effectively improve cutting efficiency.

[0047] The controller also includes a distance encoder connected to the third hydraulic cylinder, which can measure the distance the saw blade rises and falls, and feed the data back to the controller, thereby enabling solid automatic lifting control, reducing reliance on manual labor and effectively improving cutting efficiency.

[0048] A control method for a circular saw for stone cutting addresses the following industry pain points compared to existing similar mining circular saws on the market:

[0049] a. Significantly improves mining efficiency while saving energy; previously, there was no way to automatically adjust the walking speed, so the cutting could only be done at a fixed speed, and the saw was prone to jamming, jamming, burning out the motor and mechanical transmission mechanism during cutting. In order to achieve stability, low current cutting was required, resulting in low motor utilization.

[0050] b. All aspects of the cutting process can be automatically controlled, greatly reducing the labor intensity of workers.

[0051] c. Automated cutting combined with IoT remote monitoring effectively changes the mining operation environment, eliminating the need for workers to be on-site at all times, greatly improving safety and reducing accidents.

[0052] d. The machine has a high degree of intelligence and a low failure rate.

[0053] The product form of the present invention is not limited to the illustrations and embodiments shown in this case. Any appropriate changes or modifications made to it based on similar ideas should be considered as not departing from the patent scope of the present invention.

[0054] While this disclosure has been described with reference to exemplary embodiments, it should be understood that this disclosure is not limited to the disclosed exemplary embodiments. The scope of the appended claims should be interpreted in the broadest possible sense to encompass all such variations and equivalent structures and functions.

Claims

1. A circular saw for stone cutting, characterized in that: The device includes a main body; the main body includes a cutting mechanism and a supporting mechanism for the cutting mechanism; the supporting mechanism includes a support base and a set of movable wheels located below the support base; the main body also includes a control mechanism; the control mechanism includes a first drive device and a second drive device for driving the movable wheels; the movable wheels include a first wheel set and a second wheel set cooperating with the first wheel set; the first drive device also includes a first drive motor for driving the first wheel set to rotate and a second drive motor for driving the second wheel set to rotate; the control mechanism also includes a walking frequency converter connected to the first drive motor and the second drive motor and a controller connected to the walking frequency converter; the cutting mechanism includes a housing and a saw blade mounting base rotatably connected to the housing for mounting a saw blade; the saw blade mounting base includes a first locating seat and a second locating seat located on both sides of the housing; the control mechanism also includes a third drive motor for driving the first locating seat to rotate and a fourth drive motor for driving the second locating seat to rotate; the control method of the circular saw for stone cutting includes the following steps: s1. Set the preset current value: Set the preset current value A1 and the walking speed D for automatic cutting on the touch screen; s2. Obtain the current comparison value: Obtain the actual current values ​​of the first and second frequency converters during the cutting process, compare the two current values, and take the larger value as the current comparison value A2. s3. Set the frequency gain value KP and integral action parameter KI of the walking frequency converter driver; s4. Comparison Calculation: When the current comparison value is less than the preset current value, the walking frequency converter increases the output frequency by (A1-A2) / A1 multiplied by KP, thereby increasing the walking speed D; when the current comparison value is greater than the preset current value, the walking frequency converter decreases the output frequency by (A2-A1) / A1 multiplied by KP, thereby decreasing the walking speed D.

2. The circular saw for stone cutting according to claim 1, characterized in that: The control mechanism further includes a cutting control component; the cutting control component includes a first frequency converter connected to the third drive motor and a second frequency converter connected to the fourth drive motor.

3. A circular saw for stone cutting according to claim 2, characterized in that: The controller is connected to the walking frequency converter, the first frequency converter, and the second frequency converter, respectively.

4. A circular saw for stone cutting according to claim 3, characterized in that: The controller includes a touch screen and an intermediate relay.

5. A circular saw for stone cutting according to claim 4, characterized in that: The control mechanism also includes a first hydraulic cylinder that drives the first locator to extend and retract outward and a second hydraulic cylinder that drives the second locator to extend and retract outward.

6. A circular saw for stone cutting according to claim 5, characterized in that: The cutting mechanism also includes a guide rod that is vertically arranged on the support seat; the housing is slidably connected to the guide rod; the control mechanism also includes a third hydraulic cylinder that drives the housing to move up and down along the guide rod.

7. A circular saw for stone cutting according to claim 6, characterized in that: The first wheel set includes two first wheel bodies and two second wheel bodies whose rotation direction is perpendicular to the first wheel bodies; the second wheel set includes two third wheel bodies and two fourth wheel bodies whose rotation direction is perpendicular to the third wheel bodies; the second drive device also includes a fourth cylinder, a fifth cylinder, a sixth cylinder and a seventh cylinder disposed at the four corners of the support seat.

8. A circular saw for stone cutting according to claim 7, characterized in that: The control mechanism also includes a hydraulic station pump and a main control module for controlling the hydraulic station pump; the hydraulic station pump is connected to the first cylinder, the second cylinder, the third cylinder, the fourth cylinder, the fifth cylinder, the sixth cylinder, and the seventh cylinder respectively.

Images