Diamond wire sharpening device and sharpening method

Abstract

This invention discloses a diamond wire sharpening device and method. The sharpening device includes a housing, with a left spindle box and a right spindle box on opposite sides. A wire feeding follower is positioned above the left spindle box, and a wire take-up follower is positioned above the right spindle box. A first steering wheel, a second steering wheel, and a third steering wheel are sequentially arranged between the wire feeding and take-up follower. A first oilstone sharpening device is positioned between the first and second steering wheels, and a second oilstone sharpening device is positioned between the second and third steering wheels. Three sharpening oilstones of increasing hardness are clamped on the first and / or second oilstone sharpening devices. This invention has a simple structure and can monitor and control the winding tension in real time. By using oilstone sharpening devices and steering wheels installed at 90° intervals, and combining oilstones of different Rockwell hardnesses with a laser diameter gauge to adjust the oilstone feed in real time, the sharpening strength, uniformity, and efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of diamond wire manufacturing technology, and in particular to a diamond wire sharpening device and sharpening method. Background Technology

[0002] Diamond wire saw cutting technology has replaced the original slurry cutting technology as the main cutting technology in the photovoltaic industry at present due to its advantages such as high cutting efficiency and less loss when cutting hard and brittle materials such as silicon wafers.

[0003] Currently, the manufacturing process of diamond wire generally includes pretreatment (degreasing and rust removal), sandblasting and electroplating, and post-treatment (heat treatment and rust prevention). Among these, the sandblasting and electroplating processes are particularly problematic. The sandblasting process can lead to particle agglomeration on the diamond wire surface due to instability, easily causing wire breakage during cutting and increasing customer costs. Furthermore, the coating on the diamond surface can reduce cutting ability and cause other defects such as surface marks. Therefore, a sharpening process is typically performed after sandblasting of the diamond wire. This sharpening reduces irregular particles on the diamond wire surface and decreases the thickness of the diamond coating, thereby improving the product's cutting performance.

[0004] Existing diamond wire sharpening processes utilize servo motors to drive a stable feed of the whetstone, enabling the diamond wire, with a certain feeding tension and take-up speed, to cut the high-density whetstone. This reduces surface protrusions and coating thickness on the diamond wire, improving cutting efficiency, decreasing the probability of wire breakage, and reducing saw marks on the silicon wafer surface, thus enhancing product quality. However, existing diamond wire sharpening equipment often has limited sharpening configurations or rudimentary sharpening devices, resulting in lower sharpening effectiveness. Furthermore, single-sided sharpening can easily increase the ellipticity of the steel wire. Differences in diamond powder particle size and anisotropic particle distribution on the steel wire surface can lead to a diameter deviation of 1-3µm or more. This makes the steel wire prone to twisting during cutting, causing defects such as wire breakage and gaps. Summary of the Invention

[0005] Purpose of the invention: The purpose of this invention is to provide a diamond wire sharpening device with a simple structure that can improve the sharpening strength, uniformity and efficiency; another purpose of this invention is to provide a sharpening method using the above-mentioned diamond wire sharpening device.

[0006] Technical Solution: This invention provides a diamond wire sharpening device, comprising a housing. A left spindle box for wire feeding and a right spindle box for wire take-up are respectively located on both sides of the housing. A wire feeding follower is located above the left spindle box, and a wire take-up follower is located above the right spindle box. A first steering wheel, a second steering wheel, and a third steering wheel are sequentially arranged between the wire feeding and take-up follower devices. Each steering wheel is used to rotate the diamond wire 90° clockwise or counterclockwise, achieving double-sided sharpening and improving the ellipticity of the wire through this 90° rotation. A first oilstone sharpening device is located between the first and second steering wheels, and a second oilstone sharpening device is located between the second and third steering wheels. Three sharpening oilstones of increasing hardness are clamped on the first and / or second oilstone sharpening devices. Using multiple oilstones of different hardness in combination improves the sharpening strength. The left and right spindle boxes drive the wire feeding or take-up follower devices via cylinders.

[0007] As a further improvement to the above technical solution, a first laser diameter gauge is provided between the wire feeding follower and the first steering wheel, and a second laser diameter gauge is provided between the wire take-up follower and the third steering wheel. The laser diameter gauge detects the diameter difference of the steel wire before and after sharpening in real time, adjusts the feed amount of the oilstone sharpening, and improves the uniformity of the steel wire diameter.

[0008] As a further improvement to the above technical solution, a first guide roller is provided between the wire feeding and following device and the first laser diameter measuring instrument; a fourth guide roller is provided between the wire taking-up and following device and the second laser diameter measuring instrument.

[0009] As a further improvement to the above technical solution, a first tension wheel is provided between the first steering wheel and the first oilstone sharpening device; a second tension wheel is provided between the second steering wheel and the second oilstone sharpening device.

[0010] As a further improvement to the above technical solution, a swing arm and a counterweight are fixed on the first tension wheel and / or the second tension wheel. The swing arm is evenly provided with multiple mounting holes for mounting the counterweight. The tension adjustment is achieved by adjusting the mass and mounting position of the counterweight.

[0011] As a further improvement to the above technical solution, a second thread guide roller is provided between the first tension roller and the first oilstone sharpening device; a fifth thread guide roller is provided between the second tension roller and the second oilstone sharpening device.

[0012] As a further improvement to the above technical solution, the first oilstone sharpening device and / or the second oilstone sharpening device include a motor, a reducer connected to the motor, a lead screw module connected to the reducer, and a bidirectional movable worktable on the lead screw module. Three vises for clamping the sharpening oilstone are alternately installed on the worktable.

[0013] As a further improvement to the above technical solution, the hardness of the three sharpening oilstones are as follows: Rockwell hardness 3-5, Rockwell hardness 8-10 and Rockwell hardness 12-15.

[0014] As a further improvement to the above technical solution, a V-shaped rubber ring is also included. The V-shaped rubber ring is used to install on each guide wheel and / or steering wheel to reduce the torsion that occurs during the movement of the steel wire passing through the guide wheel and / or steering wheel.

[0015] On the other hand, a sharpening method of the present invention utilizing the above-mentioned diamond wire sharpening device is characterized by comprising the following steps:

[0016] (1) Adjust the tension of the first tension wheel and the second tension wheel according to the diameter and tension of the diamond wire to be sharpened; the tension of the swing arm of the tension wheel can be adjusted from 1N to 20N, and the tension fluctuation range is 50% ± 5%.

[0017] (2) Adjust the displacement of the worktable per unit time of the first and second oilstone sharpening devices according to the size of the sharpening amount, with a repeatability of ±0.001mm; the sharpening process feed rate is 0.1-4mm / min.

[0018] (3) Select the hardness of the sharpening stone. According to the threading sequence, install 3 stones in the first and second sharpening stone devices respectively, and gradually increase the hardness of the stone from front to back.

[0019] (4) Start the machine, the diamond wire is fed from the left spindle box end and wound up at the right spindle box end. The first laser diameter gauge detects the diameter of the diamond wire at the feeding end and the second laser diameter gauge detects the diameter of the diamond wire at the winding end. According to the diameter difference between the diamond wire at the feeding end and the winding end, adjust the feed speed of the first and second oilstone sharpening devices to control the diameter uniformity of the whole roll of diamond wire.

[0020] Beneficial Effects: Compared with existing technologies, the present invention has the following significant advantages: The present invention has a simple structure, can monitor and control the winding tension in real time, and reduces the twisting of the steel wire during the unwinding process through the rubber ring of the wire guide wheel. The oilstone sharpening device and steering wheel, installed at a 90° position, achieve double-sided sharpening to improve the ellipticity of the steel wire. Furthermore, by using oilstones with different Rockwell hardness adjustments, the sharpening strength and efficiency are improved. The laser diameter gauge optimizes the uniformity of the sharpening by controlling the oilstone feed in real time. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the present invention;

[0022] Figure 2 This is a schematic diagram of the structure of the oilstone sharpening device of the present invention;

[0023] Figure 3This is a schematic diagram of the diamond wire sharpening process of the present invention;

[0024] The attached diagram shows the following reference numerals: 1. Left spindle box; 2. Wire feeding follower device; 3. First wire guide roller; 4. First laser diameter gauge; 5. First steering roller; 6. First tension roller; 7. Second wire guide roller; 8. First whetstone sharpening device; 9. Second steering roller; 10. Third wire guide roller; 11. Second tension roller; 12. Second whetstone sharpening device; 13. Third steering roller; 14. Second laser diameter gauge; 15. Fourth wire guide roller; 16. Wire take-up follower device; 17. Right spindle box; 18. Motor; 19. Reducer; 20. Lead screw module; 21. Bench vise; 22. Sharpening whetstone; 23. Diamond wire; 2301. Base wire; 2302. Diamond abrasive; 2303. Metal coating. Detailed Implementation

[0025] The technical solution of the present invention will be further described below with reference to the accompanying drawings.

[0026] like Figure 1 As shown in one embodiment, a diamond wire sharpening device is provided, including a left spindle box 1 (not shown in the chassis diagram), a wire feeding follower device 2, a first wire guide spool 3, a first steering spool 5, a first whetstone sharpening device 8, a second steering spool 9, a second whetstone sharpening device 12, a third steering spool 13, a fourth wire guide spool 15, a take-up follower device 16, and a right spindle box 17. The wire feeding follower device 2 is a wire feeding I-beam; the take-up follower device 16 is a wire take-up I-beam. The left and right spindle boxes drive a pin via a cylinder to clamp the wire feeding or take-up I-beam.

[0027] The two sides of the casing are the wire feeding end and the wire taking end, respectively. The wire feeding end is used to feed out the diamond wire, and the wire taking end is used to take back the diamond wire. There is a working section between the wire feeding end and the wire taking end. The working section is equipped with a first oilstone sharpening device 8 and a second oilstone sharpening device 12 to sharpen the diamond wire.

[0028] The take-up end, starting from the machine housing, includes a left spindle housing 1, a pay-off following device 2, and a first guide roller 3; the pay-off end, also starting from the machine housing, includes a right spindle housing 17, a take-up following device 16, and a fourth guide roller 15; the left spindle housing 1 and the right spindle housing 17 are respectively located on both sides of the machine housing. The working section includes, from front to back, a first steering roller 5, a first whetstone sharpening device 8, a second steering roller 9, a second whetstone sharpening device 12, and a third steering roller 13, wherein the first steering roller 5 is closer to the pay-off end, and the third steering roller 13 is closer to the take-up end. The diamond wire starts from the pay-off following device 2 connected to the left spindle housing 1, passes sequentially through the first steering roller 5, the first whetstone sharpening device 8, the second steering roller 9, the second whetstone sharpening device 12, and the third steering roller 13, and finally winds onto the take-up following device 16 connected to the right spindle housing 17.

[0029] In this embodiment, the diamond wire sharpening device further includes a first laser diameter gauge 4 and a second laser diameter gauge 14. The first laser diameter gauge 4 is located at the wire feeding end and is used to detect the diameter of the diamond wire at the wire feeding end; the second laser diameter gauge 14 is located at the wire take-up end and is used to detect the diameter of the diamond wire at the wire take-up end. Specifically, the first laser diameter gauge 4 is located between the wire feeding follower 2 and the first steering wheel 5; the second laser diameter gauge 14 is located between the wire take-up follower 16 and the third steering wheel 13. The laser diameter gauges are used to detect the uniformity of the wire diameter sharpening in real time, thereby controlling the feed rate of the oilstone sharpening device.

[0030] In this embodiment, the diamond wire sharpening device further includes a first tension wheel 6, a second guide wheel 7, a second tension wheel 11, and a fifth guide wheel (not shown in the figure). The first tension wheel 6 is located between the first steering wheel 5 and the first oilstone sharpening device 8; the second tension wheel 11 is located between the second steering wheel 9 and the second oilstone sharpening device 12. A swing arm and a counterweight are fixed to the first tension wheel 6 and the second tension wheel 11. Multiple mounting holes are evenly distributed on the swing arm for mounting the counterweight; the mounting position of the counterweight can be adjusted forward and backward to achieve multi-tension adjustment with different masses. The second guide wheel 7 is located between the first tension wheel 6 and the first oilstone sharpening device 8; the fifth guide wheel is located between the second tension wheel 11 and the second oilstone sharpening device 12.

[0031] In this embodiment, the movement trajectory of the diamond wire from the pay-off end to the take-up end is a rectangle with a notch. The movement trajectory includes the pay-off end, the working section, and the take-up end, wherein the working section consists of a first working section and a second working section that are perpendicular to each other. To achieve the above movement trajectory, the first steering wheel 5, the second steering wheel 9, and the third steering wheel 13 are arranged at the three vertices of the rectangle in a clockwise direction. The first steering wheel 5 is installed at a 90° position relative to the first guide wheel 3; the second steering wheel 9 is installed at a 180° position relative to the first steering wheel 5; and the third steering wheel 13 is installed at a 90° position relative to the second steering wheel 9. Furthermore, the first steering wheel 5 and the second steering wheel 9 are installed at a 90° position relative to the second oilstone sharpening device 12, and the third steering wheel 13 is installed at a 90° position relative to the first oilstone sharpening device 8. The diamond wire starts from the pay-off end and moves to the first steering wheel 5. The trajectory of the diamond wire turns 90° clockwise and enters the first working section. The diamond wire continues to move forward and passes the second steering wheel 9. The trajectory of the diamond wire turns 90° clockwise and enters the second working section. The diamond wire continues to move forward and passes the third steering wheel 13. The trajectory of the diamond wire turns 90° clockwise and enters the take-up end.

[0032] like Figure 2As shown, in one embodiment, a structure for an oilstone sharpening device is provided. The oilstone sharpening device includes a motor 18, a reducer 19 connected to the motor 18, and a lead screw module 20 connected to the reducer 19. The lead screw module 20 is provided with a bidirectional movable worktable, and three vises 21 for clamping the sharpening oilstone 22 are alternately installed on the worktable. The lead screw module 20 is a ball screw module and is connected to the reducer 19 via a coupling.

[0033] Specifically, a double worktable is provided above the lead screw module 20, which can perform bidirectional precision displacement of 0.01 mm / min. A vise 21 is mounted on the worktable of the lead screw module 20, with the vises alternating between upper and lower sections. Each sharpening device has three vises. Sharpening oilstones 22 are clamped in the vises. The oilstones have different hardnesses ranging from Rockwell hardness 3 to 15, with the first oilstone having the lowest hardness and the last oilstone having the highest. Specifically, oilstone one has a Rockwell hardness range of 3-5, oilstone two has a Rockwell hardness range of 8-10, and oilstone three has a Rockwell hardness range of 12-15.

[0034] In one embodiment, each guide wheel and steering wheel is equipped with a high-hardness, wear-resistant V-shaped rubber ring. The groove diameter of the V-shaped rubber ring is adapted to the diameter of the finished diamond wire, thereby reducing the torsion of the steel wire during the movement between the guide wheels.

[0035] In one embodiment, a sharpening method using a diamond wire sharpening device is provided, comprising the following steps:

[0036] (1) Adjust the tension of the first tension wheel and the second tension wheel according to the diameter and tension of the diamond wire to be sharpened; the tension of the swing arm of the tension wheel can be adjusted from 1N to 20N, and the tension fluctuation range is 50% ± 5%.

[0037] (2) Adjust the displacement of the worktable per unit time of the first and second oilstone sharpening devices according to the size of the sharpening amount, with a repeatability of ±0.001mm; the sharpening process feed rate is 0.1-4mm / min.

[0038] (3) Select the hardness of the sharpening stone. According to the threading sequence, install 3 stones in the first and second sharpening stone devices respectively, and gradually increase the hardness of the stone from front to back.

[0039] (4) Start the machine, the diamond wire is fed from the left spindle box end and wound up at the right spindle box end. The first laser diameter gauge detects the diameter of the diamond wire at the feeding end and the second laser diameter gauge detects the diameter of the diamond wire at the winding end. According to the diameter difference between the diamond wire at the feeding end and the winding end, adjust the feed speed of the first and second oilstone sharpening devices to control the diameter uniformity of the whole roll of diamond wire.

[0040] like Figure 3As shown, before the diamond wire 23 is sharpened, a number of diamond abrasives 2302 are distributed on its base wire 2301. The base wire 2301 and the diamond abrasives 2302 are covered with a metal plating layer 2303. After being sharpened by the first oilstone device and the second oil device, the surface of the diamond wire is relatively uniformly sharpened, reducing the ellipticity of the wire.

Claims

1. A diamond wire sharpening device, characterized by, The sharpening device includes a housing, on which a left spindle box (1) for wire feeding and a right spindle box (17) for wire take-up are respectively provided on both sides. A wire feeding follower device (2) is provided above the left spindle box (1), and a wire take-up follower device (16) is provided above the right spindle box (17). A first steering wheel (5), a second steering wheel (9), and a third steering wheel (13) are arranged sequentially between the wire feeding follower device (2) and the wire take-up follower device (16). Each steering wheel is used to turn the diamond wire 90° clockwise or counterclockwise, and the 90° turn achieves double-sided sharpening to improve the ellipticity of the steel wire. A first oilstone sharpening device (8) is provided between the first steering wheel (5) and the second steering wheel (9), and a second oilstone sharpening device (12) is provided between the second steering wheel (9) and the third steering wheel (13). Three sharpening oilstones with progressively increasing hardness are clamped on the first oilstone sharpening device (8) and / or the second oilstone sharpening device (12).

2. The diamond wire sharpening device according to claim 1, wherein A first laser diameter measuring instrument (4) is provided between the line-laying follower device (2) and the first steering wheel (5), and a second laser diameter measuring instrument (14) is provided between the line-receiving follower device (16) and the third steering wheel (13).

3. The diamond wire sharpening device according to claim 2, characterized in that, A first guide roller (3) is provided between the wire feeding follower (2) and the first laser diameter measuring instrument (4); a fourth guide roller (15) is provided between the wire taking-up follower (16) and the second laser diameter measuring instrument (14).

4. The diamond wire sharpening device according to claim 1, characterized in that, A first tension wheel (6) is provided between the first steering wheel (5) and the first oilstone sharpening device (8); a second tension wheel (11) is provided between the second steering wheel (9) and the second oilstone sharpening device (12).

5. The diamond wire sharpening device according to claim 4, characterized in that, A swing arm and a counterweight are fixed on the first tension wheel (6) and / or the second tension wheel (11). The swing arm is provided with multiple mounting holes evenly distributed on it. The mounting holes are used to install the counterweight. The multi-tension adjustment is achieved by adjusting the mass and installation position of the counterweight.

6. The diamond wire sharpening device according to claim 4, characterized in that, A second thread guide wheel (7) is provided between the first tension wheel (6) and the first oilstone sharpening device (8); a fifth thread guide wheel is provided between the second tension wheel (11) and the second oilstone sharpening device (12).

7. The diamond wire sharpening device according to claim 4, characterized in that, The first oilstone sharpening device (8) and / or the second oilstone sharpening device (12) include a motor (18), a reducer (19) connected to the motor (18), and a lead screw module (20) connected to the reducer (19). The lead screw module (20) is provided with a bidirectional movable worktable, and three vises (21) for clamping the sharpening oilstone (22) are alternately installed on the worktable.

8. The diamond wire sharpening device according to claim 1, characterized in that, The hardness of the three sharpening oilstones are as follows: Rockwell hardness 3-5, Rockwell hardness 8-10, and Rockwell hardness 12-15.

9. The diamond wire sharpening device according to claim 1, characterized in that, It also includes V-shaped rubber rings, which are installed on each guide wheel and / or steering wheel to reduce the torsion that occurs during the movement of the steel wire through the guide wheel and / or steering wheel.

10. A sharpening method using the diamond wire sharpening device according to any one of claims 1-9, characterized in that, Includes the following steps: (1) Adjust the tension of the first tension wheel and the second tension wheel according to the diameter and tension of the diamond wire to be sharpened; the tension of the swing arm of the tension wheel can be adjusted from 1N to 20N, and the tension fluctuation range is 50% ± 5%. (2) Adjust the displacement of the worktable per unit time of the first and second oilstone sharpening devices according to the size of the sharpening amount, with a repeatability of ±0.001mm; the sharpening process feed rate is 0.1-4mm / min. (3) Select the hardness of the sharpening stone. According to the threading sequence, install 3 stones in the first and second sharpening stone devices respectively, and gradually increase the hardness of the stone from front to back. (4) Start the machine, the diamond wire is fed from the left spindle box end and wound up at the right spindle box end. The first laser diameter gauge detects the diameter of the diamond wire at the feeding end and the second laser diameter gauge detects the diameter of the diamond wire at the winding end. According to the diameter difference between the diamond wire at the feeding end and the winding end, adjust the feed speed of the first and second oilstone sharpening devices to control the diameter uniformity of the whole roll of diamond wire.

Images