A method for adjusting diamond wire cable-stayed in real time through image recognition

Abstract

The application discloses a method for real-time adjustment of diamond wire cable-stayed by image recognition, comprising: installing an industrial camera on a servo adjustment mechanism fixing piece on the outside of the diamond wire, above the wire roller and below the synchronous guide wheel, and adjusting to obtain a final shooting area range; installing a light source on the back plate of the take-up chamber on the inside of the diamond wire, above the wire roller and below the synchronous guide wheel; starting the slicing machine to cut the silicon rod, real-time monitoring the diamond wire to obtain a real-time diamond wire monitoring picture, and determining a left and right allowable deviation angle; the diamond wire starts to appear cable-stayed, and gradually deviates from the left or right allowable deviation angle; when it is judged that the diamond wire deviates from the left allowable deviation angle, a left deviation pulse signal is continuously output to correct the diamond wire; when it is judged that the diamond wire deviates from the right allowable deviation angle, a right deviation pulse signal is continuously output to correct the diamond wire. The application achieves the purpose of effectively correcting the diamond wire cable-stayed.

Description

Technical Field

[0001] This invention relates to the field of diamond wire multi-wire cutting technology, specifically to a method for real-time adjustment of diamond wire oblique tension through image recognition. Background Technology

[0002] The slicing machine includes a wire feeding chamber, a wire take-up chamber, and a processing chamber. The processing chamber has left, right, and lower main rollers, each with numerous sets of wire grooves. Diamond wire is laid in a right-hand spiral pattern by staggered routing on different main roller grooves. The forward and reverse rotation of the wire feeding and take-up rollers achieves forward and reverse cutting of the silicon rod. Three servo motor systems controlling the main rollers ensure that the take-up and feed rollers operate at the same linear speed, enabling stable cutting of the silicon rod under constant tension.

[0003] The winding and unwinding process is implemented with each forward and reverse cycle as a unit, and the unwinding amount is greater than the winding amount as the process condition for cutting the silicon rod. However, because the tension applied to the diamond wire during the main roller cutting is greater than the tension during the winding roller winding, the winding roller winding tension is unstable, which causes the diamond wire to be non-perpendicular to the oblique cut surface of the roller and the synchronous guide wheel, resulting in a slanted pulling phenomenon.

[0004] To address the aforementioned oblique pulling phenomenon, existing technologies passively predict oblique pulling by shifting the tension wheel in the wire feeding chamber of the slicing machine or by shifting the tension wheel in the wire taking chamber of the slicing machine. Then, a synchronization device is used to correct the shift, thereby ensuring the verticality of the diamond wire.

[0005] However, the above-mentioned existing technology has the following drawbacks: due to the insufficient detection accuracy of the tension wheel and the detection time delay, the skewed phenomenon cannot be detected and effectively corrected in time. Therefore, the skewed phenomenon still occurs from time to time when the slicing machine cuts the silicon rod. Summary of the Invention

[0006] To overcome the shortcomings of existing technologies, this invention provides a method for real-time adjustment of diamond wire skewing tension using image recognition. This method addresses the technical problems of insufficient detection accuracy and detection time delay in existing technologies when detecting diamond wire skewing tension, thereby achieving the goal of quickly and accurately identifying diamond wire skewing tension and effectively correcting it.

[0007] To solve the above problems, the technical solution adopted by the present invention is as follows:

[0008] A method for real-time adjustment of diamond wire skewing tension using image recognition includes the following steps:

[0009] Based on the position of the diamond wire between the wire roller and the synchronous guide wheel, facing the take-up and unwinding chamber, the industrial camera is mounted on the servo adjustment mechanism fixture on the outside of the diamond wire, above the wire roller, and below the synchronous guide wheel, and the mounting position of the industrial camera is adjusted to obtain a final shooting area range.

[0010] The light source is mounted on the back plate of the take-up and untake-up chamber on the inner side of the diamond wire, above the wire roller, and below the synchronous guide wheel.

[0011] The slicing machine is started to cut the silicon rod, and the industrial camera and the light source are turned on to monitor the diamond wire in real time, so as to obtain a real-time diamond wire monitoring image and determine a leftward allowable offset angle and a rightward allowable offset angle.

[0012] The diamond wire between the synchronous guide wheel and the wire roller begins to be pulled at an angle, gradually deviating from the allowable offset angle to the left or the allowable offset angle to the right.

[0013] When the diamond wire is detected to have deviated from the allowable leftward offset angle based on the real-time diamond wire monitoring screen, a leftward offset pulse signal is continuously output to correct the diamond wire until the diamond wire falls back into the allowable leftward offset angle.

[0014] When the diamond wire is detected to have deviated from the allowable rightward offset angle based on the real-time diamond wire monitoring screen, a rightward offset pulse signal is continuously output to correct the diamond wire until the diamond wire falls back into the allowable rightward offset angle.

[0015] In a preferred embodiment of the present invention, adjusting the mounting position of the industrial camera includes:

[0016] Based on the initial installation height of the industrial camera, the first distance from the industrial camera lens to the diamond wire is obtained, and the first shooting field of view height of the industrial camera lens is further obtained.

[0017] The first shooting area range of the industrial camera lens is obtained based on the first shooting field of view height and the initial installation height of the industrial camera.

[0018] Determine whether the first shooting area of ​​the industrial camera lens exceeds the starting position of the diamond wire on the synchronous guide wheel;

[0019] If not, the initial installation height of the industrial camera will not be adjusted;

[0020] If so, the initial installation height of the industrial camera is adjusted until the first shooting area of ​​the industrial camera lens does not exceed the starting position of the diamond wire on the synchronous guide wheel, thus obtaining the adjusted installation height of the industrial camera.

[0021] In a preferred embodiment of the present invention, obtaining the first field-of-view height of the industrial camera lens includes:

[0022] Based on the first distance from the industrial camera lens to the diamond wire, the model and size of the industrial camera, and the focal length of the industrial camera lens, the first shooting field of view height of the industrial camera lens is obtained, as shown in Formula 1:

[0023]

[0024] In the formula, h is the first shooting field of view height of the industrial camera lens, L is the first distance from the industrial camera lens to the diamond wire, c is the model size of the industrial camera, and f is the focal length of the industrial camera lens.

[0025] In a preferred embodiment of the present invention, after determining that the range of the first shooting area does not exceed the starting position of the diamond wire on the synchronous guide wheel, the method includes:

[0026] The thickness of the diamond wire on the wire roller is obtained, and based on the first distance from the industrial camera lens to the diamond wire, a second distance from the industrial camera lens to the diamond wire is obtained when the wire roller is no longer in use.

[0027] The second field-of-view height of the industrial camera lens is obtained based on the second distance, the model and size of the industrial camera, and the focal length of the industrial camera lens.

[0028] The second shooting area range of the industrial camera lens is obtained based on the second shooting field of view height of the industrial camera lens and the initial installation height of the industrial camera;

[0029] Determine whether the second shooting area of ​​the industrial camera lens exceeds the starting position of the diamond wire on the synchronous guide wheel;

[0030] If not, the installation height of the industrial camera will not be adjusted to obtain the final shooting area range;

[0031] If so, the installation height of the industrial camera is adjusted until the second shooting area of ​​the industrial camera lens does not exceed the starting position of the diamond wire on the synchronous guide wheel, thus obtaining the final shooting area range.

[0032] In a preferred embodiment of the present invention, after adjusting the range of the first shooting area to not exceed the starting position of the diamond wire on the synchronous guide wheel, the method includes:

[0033] The thickness of the diamond wire on the wire roller is obtained, and based on the first distance from the industrial camera lens to the diamond wire, a second distance from the industrial camera lens to the diamond wire is obtained when the wire roller is no longer in use.

[0034] The second field-of-view height of the industrial camera lens is obtained based on the second distance, the model and size of the industrial camera, and the focal length of the industrial camera lens.

[0035] The second shooting area range of the industrial camera lens is obtained based on the second shooting field of view height of the industrial camera lens and the adjusted installation height of the industrial camera.

[0036] Determine whether the second shooting area of ​​the industrial camera lens exceeds the starting position of the diamond wire on the synchronous guide wheel;

[0037] If not, the installation height of the industrial camera will not be adjusted to obtain the final shooting area range;

[0038] If so, continue to adjust the installation height of the industrial camera until the second shooting area of ​​the industrial camera lens does not exceed the starting position of the diamond wire on the synchronous guide wheel, thus obtaining the final shooting area range.

[0039] In a preferred embodiment of the present invention, determining a permissible leftward offset angle and a permissible rightward offset angle includes:

[0040] The range of vibration and jump values ​​of the diamond wire during its movement between the synchronous guide wheel and the wire roller are obtained;

[0041] Obtain the vibration range value of the diamond wire at the junction of the old and new wires;

[0042] Obtain the range of fluctuation caused by the intense friction between the diamond wire and the synchronous guide wheel during the initial stage of acceleration and deceleration;

[0043] Obtain the wear range value of the synchronous guide wheel during its service life;

[0044] The allowable offset value of the diamond wire is determined based on the jitter and bounce range value, the vibration range value, the bounce range value, and the wear range value.

[0045] The allowable offset value is divided equally to obtain the allowable offset distance to the left and the allowable offset distance to the right.

[0046] In a preferred embodiment of the present invention, after obtaining the allowable leftward offset distance and the allowable rightward offset distance, the method includes:

[0047] Based on the length of the diamond wire between the synchronous guide wheel and the wire roller before cutting, and according to the allowable leftward offset distance, the allowable leftward offset angle is obtained, as shown in Formula 2:

[0048]

[0049] In the formula, θ 左 Y is the allowable leftward offset angle. 左 J represents the allowable leftward offset distance, and J is the length of the diamond wire between the synchronous guide wheel and the wire roller before cutting.

[0050] In a preferred embodiment of the present invention, after obtaining the allowable leftward offset distance and the allowable rightward offset distance, the method includes:

[0051] Based on the length of the diamond wire between the synchronous guide wheel and the wire roller before cutting, and according to the allowable rightward offset distance, the allowable rightward offset angle is obtained, as shown in Formula 3:

[0052]

[0053] In the formula, θ 右 Y is the allowable rightward offset angle. 右 J represents the allowable rightward offset distance, and J is the length of the diamond wire between the synchronous guide wheel and the wire roller before cutting.

[0054] In a preferred embodiment of the present invention, when continuously outputting a left-biased pulse signal to correct the diamond wire, the following is included:

[0055] Obtain the reference intersection point between the diamond wire before cutting and the final shooting area, and further obtain the reference distance from the starting position of the diamond wire on the synchronous guide wheel to the reference intersection point;

[0056] The allowable left offset reference distance is obtained based on the reference distance and the allowable left offset angle, as shown in Formula 4:

[0057] y 左 =Ztanθ 左 (4);

[0058] In the formula, y 左 Z is the allowable leftward offset reference distance, and Z is the reference distance;

[0059] Obtain the left offset intersection point of the diamond wire and the final shooting area range, and further obtain the actual left offset distance from the left offset intersection point to the reference intersection point;

[0060] The difference between the actual left deviation distance and the leftward allowable offset reference distance is obtained to obtain the left deviation correction amount, and the left deviation pulse signal is continuously output to correct the diamond wire according to the left deviation correction amount.

[0061] In a preferred embodiment of the present invention, when continuously outputting a right-biased pulse signal to correct the diamond wire, the following is included:

[0062] Obtain the reference intersection point between the diamond wire before cutting and the final shooting area, and further obtain the reference distance from the starting position of the diamond wire on the synchronous guide wheel to the reference intersection point;

[0063] The allowable rightward offset reference distance is obtained based on the reference distance and the allowable rightward offset angle, as shown in Formula 4:

[0064] y 右 =Ztanθ 右 (4);

[0065] In the formula, y 右 Z is the allowable rightward offset reference distance, and Z is the reference distance;

[0066] Obtain the right offset intersection point of the diamond wire and the final shooting area range, and further obtain the actual right offset distance from the right offset intersection point to the reference intersection point;

[0067] The difference between the actual right offset distance and the allowable right offset reference distance is obtained to obtain the right offset correction amount, and the right offset pulse signal is continuously output to correct the diamond wire according to the right offset correction amount.

[0068] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0069] (1) This invention uses an industrial camera to monitor diamond wire in real time. When the diamond wire is pulled at an angle and exceeds the threshold, it can be immediately identified through the real-time diamond wire monitoring screen, so as to correct the diamond wire at an immediate time. This effectively reduces the occurrence rate of wire breakage and skipping in the wire feeding and taking-up chambers of the slicing machine. Compared with the prior art, the correction speed is faster and the correction accuracy is higher.

[0070] (2) Based on the range of shaking and jumping of the diamond wire when it moves between the synchronous guide wheel and the wire roller, the range of vibration of the diamond wire at the junction of the old and new wires, the range of jumping caused by the severe friction between the diamond wire and the synchronous guide wheel, the range of vibration of the diamond wire at the junction of the old and new wires, and the wear range of the synchronous guide wheel during its service life, the present invention sets appropriate leftward allowable offset angles and rightward allowable offset angles, so as to effectively monitor the oblique pulling of the diamond wire and ensure the service life of the slicing machine.

[0071] (3) The present invention adjusts the installation position of the industrial camera to obtain a final shooting area range, and determines the correction value of the diamond wire based on the intersection of the diamond wire and the final shooting area range, thereby adjusting the diamond wire based on the correction value to achieve effective correction of the diamond wire.

[0072] (4) The adjustment method provided by the present invention is highly flexible. By changing the installation position of the industrial camera, the model and size of the industrial camera, and the focal length of the industrial camera lens, the monitoring of the diamond wire inclined pull of different models of slicers can be met.

[0073] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0074] Figure 1 - This is a monitoring screen of the diamond wire when the diamond wire is pulled at an angle, as described in this embodiment of the invention;

[0075] Figure 2 - This is a monitoring screen of the diamond wire when it is pulled at an angle in an embodiment of the present invention;

[0076] Figure 3 - This is a schematic diagram showing the relative positions of the industrial camera and the light source in an embodiment of the present invention;

[0077] Figure 4 - This is a schematic diagram showing the relative positions of the wire roller and the synchronous guide wheel in an embodiment of the present invention;

[0078] Figure 5 - is a schematic diagram of the installation position of the industrial camera in an embodiment of the present invention;

[0079] Figure 6 - This is a diagram illustrating a method for real-time adjustment of diamond wire skewing tension via image recognition, according to an embodiment of the present invention.

[0080] Explanation of reference numerals: 1. Synchronous guide wheel; 2. Wire roller; 3. Servo adjustment mechanism fixing component; 4. Industrial camera; 5. Industrial camera lens; 6. Diamond wire; 7. Light source; 8. Final shooting area range; 9. Reference intersection point; 10. Left offset intersection point; 11. Right offset intersection point; 12. Reference distance; 13. Allowable left offset angle; 14. Allowable right offset angle; 15. Allowable left offset reference distance; 16. Allowable right offset reference distance; 17. Actual left offset distance; 18. Actual right offset distance. Detailed Implementation

[0081] The method for real-time adjustment of diamond wire skewing tension using image recognition provided by this invention, such as... Figure 6 As shown, it includes the following steps:

[0082] Step S1: As Figure 4As shown, based on the position of the diamond wire 6 between the wire roller 2 and the synchronous guide wheel 1, facing the take-up and unwinding chamber, the industrial camera 4 is mounted on the servo adjustment mechanism fixing part 3 on the outside of the diamond wire 6, above the wire roller 2 and below the synchronous guide wheel 1, and the mounting position of the industrial camera 4 is adjusted to obtain a final shooting area range 8.

[0083] Step S2: Install the light source 7 on the back plate of the take-up and untake-up chamber, inside the diamond wire 6, above the wire roller 2, and below the synchronous guide wheel 1, as shown. Figure 3 and Figure 5 As shown;

[0084] Step S3: Start the slicing machine to cut the silicon rod, and turn on the industrial camera 4 and the light source 7 to monitor the diamond wire 6 in real time, obtain a real-time diamond wire monitoring image, and determine a leftward allowable offset angle 13 and a rightward allowable offset angle 14.

[0085] Step S4: The diamond wire 6 between the synchronous guide wheel 1 and the wire roller 2 begins to be pulled at an angle, gradually deviating from the allowable offset angle 13 to the left or the allowable offset angle 14 to the right;

[0086] Step S5: When it is determined from the real-time diamond wire monitoring screen that the diamond wire 6 has deviated from the leftward allowable offset angle 13, the left offset pulse signal is continuously output to correct the diamond wire 6 until the diamond wire 6 falls back into the leftward allowable offset angle 13.

[0087] Step S6: When it is determined from the real-time diamond wire monitoring screen that the diamond wire 6 has deviated from the rightward allowable offset angle 14, the rightward offset pulse signal is continuously output to correct the diamond wire 6 until the diamond wire 6 falls back into the rightward allowable offset angle 14.

[0088] In step S1 above, adjusting the mounting position of the industrial camera 4 includes:

[0089] Based on the initial installation height of the industrial camera 4, the first distance from the industrial camera lens 5 to the diamond wire 6 is obtained, and the first shooting field of view height of the industrial camera lens 5 is further obtained.

[0090] The first shooting area range of the industrial camera lens 5 is obtained based on the first shooting field height and the initial installation height of the industrial camera 4.

[0091] Determine whether the first shooting area of ​​the industrial camera lens 5 exceeds the starting position of the diamond wire 6 on the synchronous guide wheel 1;

[0092] If not, the initial mounting height of industrial camera 4 will not be adjusted;

[0093] If so, the initial installation height of the industrial camera 4 is adjusted until the first shooting area of ​​the industrial camera lens 5 does not exceed the starting position of the diamond wire 6 on the synchronous guide wheel 1, thus obtaining the adjusted installation height of the industrial camera 4.

[0094] Furthermore, when obtaining the first field-of-view height of the industrial camera lens 5, it includes:

[0095] Based on the first distance from the industrial camera lens 5 to the diamond wire 6, the model and size of the industrial camera 4, and the focal length of the industrial camera lens 5, the first shooting field of view height of the industrial camera lens 5 is obtained, specifically as follows:

[0096] As shown in Equation 1:

[0097]

[0098] In the formula, h is the first shooting field of view height of the industrial camera lens 5, L is the first distance from the industrial camera lens 5 to the diamond wire 6, c is the model size of the industrial camera 4, and f is the focal length of the industrial camera lens 5.

[0099] Specifically, in practical use, the industrial camera 4 can have a size of 4.8mm, and the industrial camera lens 5 can have a focal length of 50mm. When the shooting field of view height is 20mm, the distance from the industrial camera lens 5 to the diamond wire 6 is 208.3mm. Based on the above parameters, the distance between the light source 7 and the diamond wire 6 is generally 45mm.

[0100] Furthermore, after determining that the range of the first shooting area does not exceed the starting position of the diamond wire 6 on the synchronous guide wheel 1, it includes:

[0101] The thickness of diamond wire 1 on the wire roller 2 is obtained, and based on the first distance from the industrial camera lens 5 to the diamond wire 6, the second distance from the industrial camera lens 5 to the diamond wire 6 at the end of the use of the wire roller 2 is obtained.

[0102] Based on the second distance, the model and size of the industrial camera 4, and the focal length of the industrial camera lens 5, the second shooting field of view height of the industrial camera lens 5 is obtained;

[0103] The second shooting area range of the industrial camera lens 5 is obtained based on the second shooting field height of the industrial camera lens 5 and the initial installation height of the industrial camera 4.

[0104] Determine whether the second shooting area of ​​the industrial camera lens 5 exceeds the starting position of the diamond wire 6 on the synchronous guide wheel 1;

[0105] If not, the installation height of the industrial camera 4 will not be adjusted to obtain the final shooting area range 8;

[0106] If so, the installation height of the industrial camera 4 is adjusted until the second shooting area of ​​the industrial camera lens 5 does not exceed the starting position of the diamond wire 6 on the synchronous guide wheel 1, thus obtaining the final shooting area range 8.

[0107] Furthermore, after adjusting the first shooting area to no more than the starting position of the diamond wire 6 on the synchronous guide wheel 1, it includes:

[0108] The thickness of the diamond wire 6 on the roller 2 is obtained, and based on the first distance from the industrial camera lens 5 to the diamond wire 6, the second distance from the industrial camera lens 5 to the diamond wire 6 at the end of the use of the roller 2 is obtained.

[0109] Based on the second distance, the model and size of the industrial camera 4, and the focal length of the industrial camera lens 5, the second shooting field of view height of the industrial camera lens 5 is obtained;

[0110] The second shooting area range of the industrial camera lens 5 is obtained based on the second shooting field height of the industrial camera lens 5 and the adjusted installation height of the industrial camera 4.

[0111] Determine whether the second shooting area of ​​the industrial camera lens 5 exceeds the starting position of the diamond wire 6 on the synchronous guide wheel 1;

[0112] If not, the installation height of the industrial camera 4 will not be adjusted to obtain the final shooting area range 8;

[0113] If so, continue to adjust the installation height of the industrial camera 4 until the second shooting area of ​​the industrial camera lens 5 does not exceed the starting position of the diamond wire 6 on the synchronous guide wheel 1, thus obtaining the final shooting area range 8.

[0114] Specifically, in actual use, the thickness of the diamond wire 6 on the wire roller 2 gradually decreases as the wire is laid out. As the thickness decreases, the distance between the diamond wire 6 and the industrial camera lens 5 increases. According to Formula 1, this increased distance leads to a higher field of view for the industrial camera lens 5. Therefore, as the wire is laid out, the field of view may exceed the initial position of the diamond wire 6 on the synchronous guide roller 1. Thus, when adjusting the installation position of the industrial camera 4, the thickness change of the diamond wire 6 during the use of the wire roller 2 must be taken into account to ensure that the shooting area does not exceed the initial position of the diamond wire 6 on the synchronous guide roller 1 throughout the monitoring process. In practice, the thickness change of the wire roller 2 from the initial stage to the end of use is generally 7.5mm. Based on the specific parameters mentioned above and Formula 1, the distance range from the industrial camera lens 5 to the diamond wire 6 from the initial stage to the end of use is 208.3-215.8mm, and the field of view range is 20-20.72mm.

[0115] Specifically, in this invention, it is necessary to ensure that the final shooting area 8 does not exceed the starting position of the diamond wire 6 on the synchronous guide wheel 1, for the following reasons:

[0116] Monitoring principle of this invention:

[0117] (1) By determining a leftward allowable offset angle 13 and a rightward allowable offset angle 14, and then determining the reference intersection point 9 based on the intersection point of the diamond wire 6 when it is not obliquely pulled and the upper edge of the final shooting area range 8, such as... Figure 1 As shown, the reference distance 12 from the starting position of the diamond wire 6 on the synchronous guide wheel 1 to the reference intersection point 9 is further obtained;

[0118] (2) Based on the reference distance 12, the allowable leftward offset angle 13, and the allowable rightward offset angle 14, the allowable leftward offset reference distance 15 and the allowable rightward offset reference distance 16 of the diamond wire 6 at the upper edge of the final shooting area can be obtained, such as Figure 2 As shown;

[0119] (3) Determine the left offset intersection point 10 and the right offset intersection point 11 based on the intersection point of the diamond wire 6 when it is pulled diagonally with the upper edge of the final shooting area 8. Further obtain the distances from the left offset intersection point 10 and the right offset intersection point 11 to the reference intersection point 9, which are the actual left offset distance 17 and the actual right offset distance 18. Figure 2 As shown;

[0120] (4) The difference between the actual left offset distance 17 and the left allowable offset reference distance 15 is the left offset correction amount. The difference between the actual right offset distance 18 and the right allowable offset reference distance 16 is the right offset correction amount.

[0121] As can be seen from the above monitoring principle, in order to effectively monitor the diamond wire 6 in this invention, the diamond wire 6 must intersect with the upper edge of the final shooting area 8 (if it exceeds the starting position of the diamond wire 6 on the synchronous guide wheel 1, the diamond wire 6 will not intersect with the upper edge of the final shooting area 8). Thus, based on the intersection of the diamond wire 6 with the upper edge of the shooting area 8 when it is not pulled at an angle and the intersection of the diamond wire 6 with the upper edge of the shooting area 8 when it is pulled at an angle, the corresponding correction amount is obtained, and the diamond wire 6 is effectively monitored and corrected.

[0122] In step S3 above, determining a leftward allowable offset angle 13 and a rightward allowable offset angle 14 includes:

[0123] Obtain the range values ​​of jitter and bounce that exist when the diamond wire 6 moves between the synchronous guide wheel 1 and the wire roller 2;

[0124] Obtain the vibration range value of diamond wire 6 at the junction of the old and new wires;

[0125] Obtain the range of vibration caused by the intense friction between the diamond wire 6 and the synchronous guide wheel 1 during the initial stage of acceleration and deceleration;

[0126] Obtain the wear range value of synchronous guide wheel 1 during its service life;

[0127] The allowable offset value of diamond wire 6 is determined based on the values ​​of jitter and bounce range, vibration range, bounce range, and wear range.

[0128] Divide the allowable offset value into two equal parts to obtain the allowable offset distance to the left and the allowable offset distance to the right.

[0129] Specifically, in actual use, the vibration range of the diamond wire 6 at the junction of the old and new wires will be relatively large, generally 0-1mm; the jump range caused by the intense friction between the diamond wire 6 and the synchronous guide wheel 1 during the initial acceleration and deceleration phase will be relatively small, generally 0-0.2mm; the wear range of the synchronous guide wheel 1 during its service life will generally reach 2mm, and when the wear range exceeds 2mm, the synchronous guide wheel 1 will be replaced immediately. In summary, the allowable unidirectional offset distance of the diamond wire 6 should be greater than or equal to 2mm. Considering the vibration and jump of the diamond wire 6 when moving between the synchronous guide wheel 1 and the wire roller 2, in actual use, the allowable leftward and rightward offset distances are generally set to 2.5mm. These settings are not too small, which would cause the diamond wire 6 to output pulse signals to correct itself even when it is in a normal jumping state during operation, resulting in excessively frequent corrections and shortening the lifespan of the slicer. The above settings will not be set too high, thus failing to effectively monitor the diamond wire 6 inclined tension, and further preventing the elimination or prevention of various abnormal problems caused by the inclined tension.

[0130] Furthermore, after obtaining the allowed leftward offset distance and the allowed rightward offset distance, the following is included:

[0131] Based on the length of the diamond wire 6 between the synchronous guide roller 1 and the wire roller 2 before cutting, and according to the allowable leftward offset distance, the allowable leftward offset angle 13 is obtained, as shown in Formula 2:

[0132]

[0133] In the formula, θ 左 The allowable offset angle to the left is 13, Y 左 J represents the allowable offset distance to the left, and J is the length of the diamond wire 6 between the synchronous guide wheel 1 and the wire roller 2 before cutting.

[0134] Furthermore, after obtaining the allowed leftward offset distance and the allowed rightward offset distance, the following is included:

[0135] Based on the length of the diamond wire 6 between the synchronous guide roller 1 and the wire roller 2 before cutting, and according to the allowable rightward offset distance, the allowable rightward offset angle 14 is obtained, as shown in Formula 3:

[0136]

[0137] In the formula, θ 右 The allowable offset angle to the right is 14, Y 右 J represents the allowable offset distance to the right, and J is the length of the diamond wire 6 between the synchronous guide wheel 1 and the wire roller 2 before cutting.

[0138] Furthermore, when continuously outputting a left-biased pulse signal to correct the diamond wire 6, it includes:

[0139] Obtain the reference intersection point 9 between the diamond wire 6 before cutting and the final shooting area range 8, and further obtain the reference distance 12 from the starting position of the diamond wire 6 on the synchronous guide wheel 1 to the reference intersection point 9;

[0140] The allowable left offset reference distance 15 is obtained based on the reference distance 12 and the allowable left offset angle 13, as shown in Formula 4:

[0141] y 左 =Ztanθ 左 (4);

[0142] In the formula, y 左 The allowable offset to the left is 15, and Z is the reference distance of 12;

[0143] Obtain the left offset intersection point 10 of the diamond wire 6 and the final shooting area range 8, and further obtain the actual left offset distance 17 from the left offset intersection point 10 to the reference intersection point 9;

[0144] The difference between the actual left offset distance 17 and the allowable left offset reference distance 15 is obtained to obtain the left offset correction amount, and the left offset pulse signal is continuously output to correct the diamond wire 6 according to the left offset correction amount.

[0145] Furthermore, when continuously outputting a right-biased pulse signal to correct the diamond wire 6, the following includes:

[0146] Obtain the reference intersection point 9 between the diamond wire 6 before cutting and the final shooting area range 8, and further obtain the reference distance 12 from the starting position of the diamond wire 6 on the synchronous guide wheel 1 to the reference intersection point 9;

[0147] The allowable rightward offset reference distance 16 is obtained based on the reference distance 12 and the allowable rightward offset angle 14, as shown in Formula 4:

[0148] y 右 =Ztanθ 右 (4);

[0149] In the formula, y 右 The allowable offset to the right is 16, and Z is the reference distance of 12;

[0150] Obtain the right offset intersection point 11 of the diamond wire 6 and the final shooting area range 8, and further obtain the actual right offset distance 18 from the right offset intersection point 11 to the reference intersection point 9;

[0151] The difference between the actual right offset distance 18 and the rightward allowable offset reference distance 16 is obtained to obtain the right offset correction amount, and the right offset pulse signal is continuously output to correct the diamond wire 6 according to the right offset correction amount.

[0152] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0153] (1) This invention uses an industrial camera to monitor diamond wire in real time. When the diamond wire is pulled at an angle and exceeds the threshold, it can be immediately identified through the real-time diamond wire monitoring screen, so as to correct the diamond wire at an immediate time. This effectively reduces the occurrence rate of wire breakage and skipping in the wire feeding and taking-up chambers of the slicing machine. Compared with the prior art, the correction speed is faster and the correction accuracy is higher.

[0154] (2) Based on the range of shaking and jumping of the diamond wire when it moves between the synchronous guide wheel and the wire roller, the range of vibration of the diamond wire at the junction of the old and new wires, the range of jumping caused by the severe friction between the diamond wire and the synchronous guide wheel, the range of vibration of the diamond wire at the junction of the old and new wires, and the wear range of the synchronous guide wheel during its service life, the present invention sets appropriate leftward allowable offset angles and rightward allowable offset angles, so as to effectively monitor the oblique pulling of the diamond wire and ensure the service life of the slicing machine.

[0155] (3) The present invention adjusts the installation position of the industrial camera to obtain a final shooting area range, and determines the correction value of the diamond wire based on the intersection of the diamond wire and the final shooting area range, thereby adjusting the diamond wire based on the correction value to achieve effective correction of the diamond wire.

[0156] (4) The adjustment method provided by the present invention is highly flexible. By changing the installation position of the industrial camera, the model and size of the industrial camera, and the focal length of the industrial camera lens, the monitoring of the diamond wire inclined pull of different models of slicers can be met.

[0157] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A method for real-time adjustment of diamond wire skewing tension using image recognition, characterized in that, Includes the following steps: Based on the position of the diamond wire between the wire roller and the synchronous guide wheel, facing the take-up and unwinding chamber, the industrial camera is mounted on the servo adjustment mechanism fixture on the outside of the diamond wire, above the wire roller, and below the synchronous guide wheel, and the mounting position of the industrial camera is adjusted to obtain a final shooting area range. The light source is mounted on the back plate of the take-up and untake-up chamber on the inner side of the diamond wire, above the wire roller, and below the synchronous guide wheel. The slicing machine is started to cut the silicon rod, and the industrial camera and the light source are turned on to monitor the diamond wire in real time, so as to obtain a real-time diamond wire monitoring image and determine a leftward allowable offset angle and a rightward allowable offset angle. The diamond wire between the synchronous guide wheel and the wire roller begins to be pulled at an angle, gradually deviating from the allowable offset angle to the left or the allowable offset angle to the right. When the diamond wire is detected to have deviated from the allowable leftward offset angle based on the real-time diamond wire monitoring screen, a leftward offset pulse signal is continuously output to correct the diamond wire until the diamond wire falls back into the allowable leftward offset angle. When the diamond wire is detected to have deviated from the allowable rightward offset angle based on the real-time diamond wire monitoring screen, a rightward offset pulse signal is continuously output to correct the diamond wire until the diamond wire falls back into the allowable rightward offset angle.

2. The method for real-time adjustment of diamond wire inclined tension using image recognition according to claim 1, characterized in that, Adjusting the mounting position of the industrial camera includes: Based on the initial installation height of the industrial camera, the first distance from the industrial camera lens to the diamond wire is obtained, and the first shooting field of view height of the industrial camera lens is further obtained. The first shooting area range of the industrial camera lens is obtained based on the first shooting field of view height and the initial installation height of the industrial camera. Determine whether the first shooting area of ​​the industrial camera lens exceeds the starting position of the diamond wire on the synchronous guide wheel; If not, the initial installation height of the industrial camera will not be adjusted; If so, the initial installation height of the industrial camera is adjusted until the first shooting area of ​​the industrial camera lens does not exceed the starting position of the diamond wire on the synchronous guide wheel, thus obtaining the adjusted installation height of the industrial camera.

3. The method for real-time adjustment of diamond wire inclined tension via image recognition according to claim 2, characterized in that, When obtaining the first field-of-view height of the industrial camera lens, the following is included: Based on the first distance from the industrial camera lens to the diamond wire, the model and size of the industrial camera, and the focal length of the industrial camera lens, the first shooting field of view height of the industrial camera lens is obtained, as shown in Formula 1: （1）； In the formula, The first field of view height of the industrial camera lens. The first distance from the industrial camera lens to the diamond wire is [missing information]. The model and dimensions of the industrial camera are specified. Let be the focal length of the industrial camera lens.

4. The method for real-time adjustment of diamond wire skewing tension via image recognition according to claim 3, characterized in that, After determining that the range of the first shooting area does not exceed the starting position of the diamond wire on the synchronous guide wheel, the process includes: The thickness of the diamond wire formed on the wire roller is obtained, and based on the first distance from the industrial camera lens to the diamond wire, the second distance from the industrial camera lens to the diamond wire at the end of the use of the wire roller is obtained. The second field-of-view height of the industrial camera lens is obtained based on the second distance, the model and size of the industrial camera, and the focal length of the industrial camera lens. The second shooting area range of the industrial camera lens is obtained based on the second shooting field of view height of the industrial camera lens and the initial installation height of the industrial camera; Determine whether the second shooting area of ​​the industrial camera lens exceeds the starting position of the diamond wire on the synchronous guide wheel; If not, the installation height of the industrial camera will not be adjusted to obtain the final shooting area range; If so, the installation height of the industrial camera is adjusted until the second shooting area of ​​the industrial camera lens does not exceed the starting position of the diamond wire on the synchronous guide wheel, thus obtaining the final shooting area range.

5. The method for real-time adjustment of diamond wire skewing tension via image recognition according to claim 3, characterized in that, After adjusting the first shooting area to not exceed the starting position of the diamond wire on the synchronous guide wheel, the process includes: The thickness of the diamond wire formed on the wire roller is obtained, and based on the first distance from the industrial camera lens to the diamond wire, the second distance from the industrial camera lens to the diamond wire at the end of the use of the wire roller is obtained. The second field-of-view height of the industrial camera lens is obtained based on the second distance, the model and size of the industrial camera, and the focal length of the industrial camera lens. The second shooting area range of the industrial camera lens is obtained based on the second shooting field of view height of the industrial camera lens and the adjusted installation height of the industrial camera. Determine whether the second shooting area of ​​the industrial camera lens exceeds the starting position of the diamond wire on the synchronous guide wheel; If not, the installation height of the industrial camera will not be adjusted to obtain the final shooting area range; If so, continue to adjust the installation height of the industrial camera until the second shooting area of ​​the industrial camera lens does not exceed the starting position of the diamond wire on the synchronous guide wheel, thus obtaining the final shooting area range.

6. The method for real-time adjustment of diamond wire inclined tension using image recognition according to claim 1, characterized in that, When determining a permissible leftward offset angle and a permissible rightward offset angle, the following are included: The range of vibration and jump values ​​of the diamond wire during its movement between the synchronous guide wheel and the wire roller are obtained; Obtain the vibration range value of the diamond wire at the junction of the old and new wires; Obtain the range of fluctuation caused by the intense friction between the diamond wire and the synchronous guide wheel during the initial stage of acceleration and deceleration; Obtain the wear range value of the synchronous guide wheel during its service life; The allowable offset value of the diamond wire is determined based on the jitter and bounce range value, the vibration range value, the bounce range value, and the wear range value. The allowable offset value is divided equally to obtain the allowable offset distance to the left and the allowable offset distance to the right.

7. The method for real-time adjustment of diamond wire inclined tension via image recognition according to claim 6, characterized in that, After obtaining the allowed leftward offset distance and the allowed rightward offset distance, the following is included: Based on the length of the diamond wire between the synchronous guide wheel and the wire roller before cutting, and according to the allowable leftward offset distance, the allowable leftward offset angle is obtained, as shown in Formula 2: （2）； In the formula, The leftward allowable offset angle, The leftward allowable offset distance, The length of the diamond wire between the synchronous guide wheel and the wire roller before cutting.

8. The method for real-time adjustment of diamond wire inclined tension via image recognition according to claim 6, characterized in that, After obtaining the allowed leftward offset distance and the allowed rightward offset distance, the following is included: Based on the length of the diamond wire between the synchronous guide wheel and the wire roller before cutting, and according to the allowable rightward offset distance, the allowable rightward offset angle is obtained, as shown in Formula 3: （3）； In the formula, The rightward allowable offset angle, The allowable rightward offset distance, The length of the diamond wire between the synchronous guide wheel and the wire roller before cutting.

9. The method for real-time adjustment of diamond wire inclined tension via image recognition according to claim 7, characterized in that, When continuously outputting a left-biased pulse signal to correct the diamond wire, the following steps are included: Obtain the reference intersection point between the diamond wire before cutting and the final shooting area, and further obtain the reference distance from the starting position of the diamond wire on the synchronous guide wheel to the reference intersection point; The allowable left offset reference distance is obtained based on the reference distance and the allowable left offset angle, as shown in Formula 4: （4）； In the formula, The leftward allowable offset reference distance, The reference distance; Obtain the left offset intersection point of the diamond wire and the final shooting area range, and further obtain the actual left offset distance from the left offset intersection point to the reference intersection point; The difference between the actual left deviation distance and the leftward allowable offset reference distance is obtained to obtain the left deviation correction amount, and the left deviation pulse signal is continuously output to correct the diamond wire according to the left deviation correction amount.

10. The method for real-time adjustment of diamond wire inclined tension via image recognition according to claim 8, characterized in that, When continuously outputting a right-biased pulse signal to correct the diamond wire, the following steps are included: Obtain the reference intersection point between the diamond wire before cutting and the final shooting area, and further obtain the reference distance from the starting position of the diamond wire on the synchronous guide wheel to the reference intersection point; The allowable rightward offset reference distance is obtained based on the reference distance and the allowable rightward offset angle, as shown in Formula 4-1: （4-1）； In the formula, The rightward allowable offset reference distance, The reference distance; Obtain the right offset intersection point of the diamond wire and the final shooting area range, and further obtain the actual right offset distance from the right offset intersection point to the reference intersection point; The difference between the actual right offset distance and the allowable right offset reference distance is obtained to obtain the right offset correction amount, and the right offset pulse signal is continuously output to correct the diamond wire according to the right offset correction amount.

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