A multi-wire cutting machine automatic wire deviation correction device and method

Abstract

The present invention provides an automatic wire arrangement and correction method for a multi-wire cutting machine, comprising a PLC controller and a wire-taking and unwinding roller mechanism connected to the PLC controller, a wire arrangement and correction mechanism, a tension adjustment mechanism, and a tension monitoring mechanism; the wire-taking and unwinding roller mechanism is used for reciprocating routing of the cutting wire; the wire-arranging and correction mechanism comprises a correction device and a wire-arranging guide wheel group, and the wire-arranging guide wheel group is used for routing the cutting wire; the head end wire-arranging guide wheel in the wire-arranging guide wheel group is driven by the correction device to move along the routing direction of the cutting wire; the head end wire-arranging guide wheel comprises a first force sensor; the tension detection mechanism comprises a second force sensor, and the second force sensor is arranged on the tail end wire-arranging guide wheel in the wire-arranging guide wheel group; the force sensing difference between the first force sensor and the second force sensor is the movement amount of the correction device; the tension adjustment mechanism acts on the wire-arranging guide wheel group to make the cutting wire reach a preset tension.

Description

Technical Field

[0001] The present application relates to the technical field of multi-wire cutting equipment, and in particular to an automatic wire deviation correction device and method for a multi-wire cutting machine. Background Art

[0002] Multi-wire saws are widely used in slicing hard and brittle materials such as sapphire and solar silicon wafers. Diamond cutting wire is released from a pay-off roller, passed through a series of guide wheels, and then wound onto a roller. It is then wound through parallel grooves on the roller into an evenly spaced parallel cutting wire net. The wire net is then wound onto a take-up roller through a series of guide wheels. A motor applies torque to each roller to rotate it, allowing the diamond cutting wire net to achieve high-speed reciprocating motion, cutting the workpiece into hundreds or thousands of thin slices at a time. Since multi-wire saws use a reciprocating routing mode, with the pay-off and take-up rollers alternately performing the winding and unwinding actions, a wire arrangement mechanism is required to evenly arrange the cutting wires on the pay-off and take-up rollers. However, during use, wire arrangement deviations may occur, with the cutting wires stacking or being under-arranged, resulting in unstable cutting wire tension and, in severe cases, wire breakage. Therefore, a wire arrangement automatic deviation correction device and method that is easy to control, fast in response, and highly accurate is needed to achieve uniform arrangement of the cutting wires on the pay-off and take-up rollers, ensure stable cutting tension, and reduce the risk of wire breakage. Summary of the Invention

[0003] In view of the disadvantage of the offset phenomenon existing in the wire arrangement mechanism of the existing multi-wire cutting machine, the main technical problem to be solved by the present invention is to provide a wire arrangement automatic correction device and method for the multi-wire cutting machine, which can detect whether the cutting line is offset and automatically adjust the position of the wire arrangement guide wheel.

[0004] In order to solve the above technical problems, the present application provides a device and method for automatically correcting the deviation of wire arrangement of a multi-wire saw, which adopts the following technical solutions:

[0005] A wire arrangement and automatic deviation correction device for a multi-wire cutting machine, comprising a PLC controller and a wire-reeling and wire-unreeling roller mechanism connected to the PLC controller, a wire arrangement and deviation correction mechanism, a tension adjustment mechanism, and a tension monitoring mechanism;

[0006] The retractable roller mechanism is used for reciprocating cutting line routing; the wire arrangement and correction mechanism includes a correction device and a wire arrangement guide wheel assembly, the wire arrangement guide wheel assembly is used for cutting line routing; the wire arrangement guide wheel at the head end of the wire arrangement guide wheel assembly is driven by the correction device to move along the cutting line routing direction;

[0007] The head-end wire guide wheel includes a first force sensor; the tension detection mechanism includes a second force sensor, and the second force sensor is arranged on the tail-end wire guide wheel in the wire guide wheel assembly; the difference in force sensing between the first force sensor and the second force sensor is used as the movement amount of the correction device;

[0008] The tension adjustment mechanism acts on the wire guide wheel assembly to make the cutting wire reach a preset tension.

[0009] In a preferred embodiment, the tension adjustment mechanism includes a tension swing arm; one of the wire guide wheels excluding the first and last wire guide wheels in the wire guide wheel assembly is fixed to the tension swing arm;

[0010] The tension swing arm drives one of the wire wheels to swing left and right, so that the cutting line reaches a preset tension.

[0011] In a preferred embodiment, one of the wire pulleys disposed on the tension swing arm is a second wire pulley located after the tail wire guide pulley.

[0012] In a preferred embodiment, the PLC controller is connected to the first force sensor and the second force sensor to collect the force sensing values ​​of the first force sensor and the second force sensor in real time.

[0013] In a preferred embodiment, the deviation correction device is a screw slide module, which includes a drive motor, a connecting rod and a slide, and the head end wire guide wheel is fixed on the connecting rod;

[0014] The driving motor drives the connecting rod to move along the length direction of the slide, so that the head-end wire guide wheel has a movement amount.

[0015] In a preferred embodiment, the line arrangement and correction mechanism is located above the wire-reeling roller mechanism, and the correction device, the tension adjustment mechanism, and the tension monitoring mechanism are sequentially arranged along the cutting line routing direction.

[0016] In a preferred embodiment, the cable guide wheel of the cable guide wheel assembly has a winding portion; the winding portion of the corresponding cable guide wheel is installed on the head of each of the first force sensor and the second force sensor.

[0017] A method for automatically correcting the wire arrangement of a multi-wire cutting machine is provided, using any one of the aforementioned automatic wire arrangement correcting devices; the method comprising the following steps:

[0018] Step 1: After the device is started, the tension adjustment mechanism acts on the wire guide wheel assembly with a given torque, driving the cutting wire on the wire guide wheel assembly to make the cutting wire reach a preset tension;

[0019] Step 2: The PLC controller collects the force value of the cutting line acting on the wire guide wheel corresponding to the wire guide wheel assembly in real time through the first force sensor and the second force sensor;

[0020] Step 3: The PLC controller determines the offset direction of the wire on the wire guide wheel based on the collected force value and the set value;

[0021] In step 4, the PLC controller uses the difference in force between the first force sensor and the second force sensor as the correction movement amount of the correction device.

[0022] In a preferred embodiment, in step 2, the force value collected by the first force sensor or the second force sensor is the force exerted by the cutting wire with a preset tension on its corresponding wire guide wheel.

[0023] In a preferred embodiment, in step 4, the deviation-correcting device includes a driving motor; the deviation-correcting device is a correction value of the driving motor.

[0024] In summary, this application has the following beneficial effects:

[0025] The present invention provides an automatic wire traversing deviation correction device and method based on force sensors. Two force sensors installed in different positions are used to determine whether the cutting line is offset, and the position of the wire traversing guide wheel is automatically corrected, so that the landing point of the wire traversing guide wheel and the position of the cutting line remain basically perpendicular, and the cutting line is evenly arranged on the retractable roller, thereby avoiding wire breakage failures, reducing the risk of wire breakage, and improving the stability of equipment operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the overall structure of the automatic cable deviation correction device according to an embodiment of the present invention;

[0027] Figure 2 This is a structural schematic diagram of the cable guide wheel assembly according to an embodiment of the present invention;

[0028] Figure 3 This is a structural diagram of the tension monitoring mechanism according to an embodiment of the present invention;

[0029] Figure 4 This is a schematic diagram of the winding of the diamond cutting wire according to an embodiment of the present invention;

[0030] Figure 5 This is a schematic diagram of the forward deflection of the cable arrangement according to an embodiment of the present invention;

[0031] Figure 6 Schematic diagram of the cable being offset backward according to an embodiment of the present invention.

[0032] Explanation of the accompanying reference numerals: 1. Servo motor for retracting and unreeling roller; 2. Servo motor support; 3. Coupling; 4. Bearing support; 5. Wire roller; 6. Wire arrangement servo motor; 7. Screw slide module; 8. Connecting rod; 9. Wire arrangement guide wheel assembly; 10. Diamond cutting wire; 11. One of the wire arrangement guide wheels; 12. Tension swing arm; 13. Servo motor for tension swing arm; 14. Wire storage chamber frame plate; 15. Pass pulley; 16. Tension monitoring mechanism; 17. Connecting rod; 18. Wire guide wheel.

[0033] 9. Wire routing guide wheel assembly; 901. First-end wire routing guide wheel mounting cover; 902. First-end wire routing guide wheel; 903. First mounting nut; 904. First force sensor; 905. First force sensor outlet.

[0034] 16. Tension monitoring mechanism; 1601. Tail end cable guide wheel mounting cover; 1602. Tail end cable guide wheel; 1603. Second mounting nut; 1604. Fixing seat; 1605. Second force sensor; 1606. Second force sensor outlet. DETAILED DESCRIPTION

[0035] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0036] In the description of the present invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0037] In the description of the present invention, it should be noted that, unless otherwise clearly stipulated and limited, the terms "installed", "provided with", "set / connected", "connected", etc. should be understood in a broad sense. For example, "connection" can be a wall-mounted connection, a detachable connection, or an integral connection. It can be a mechanical connection or an electrical connection. It can be a direct connection or an indirect connection through an intermediate medium. It can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0038] The following is combined with Figure 1-6 Provide further details on this application.

[0039] like Figure 1 As shown in Figure 4, an automatic wire arrangement and correction device for a multi-wire cutting machine consists of a pay-and-reel roller mechanism, a wire arrangement and correction mechanism, a tension adjustment mechanism, and a tension monitoring mechanism 16. The pay-and-reel roller 5 of the pay-and-reel roller mechanism is secured by two bearing supports 4. The pay-and-reel roller servo motor 1 is secured to the servo motor support 2. The pay-and-reel roller 5 is connected to the shaft of the pay-and-reel roller servo motor 1 via a coupling 3.

[0040] The wire arrangement and correction mechanism is fixed above the wire reeling and unwinding roller mechanism. The screw slide module 7 in the wire arrangement and correction mechanism is fixed to the wire storage chamber frame plate 14 by bolts. The shaft extension end of the wire arrangement servo motor 6 is fixed to the flange seat of the screw slide module 7 and is connected to the connecting rod shaft through a coupling. The connecting rod 8 is installed on the slide of the screw slide module 7.

[0041] The wire routing guide wheel group in the wire routing and correction mechanism, wherein the head end wire routing guide wheel 902 is installed on the head of the first force sensor 904 with the help of the head end wire routing guide wheel mounting cover 901, and the head end wire routing guide wheel 902 of the wire routing guide wheel group 9 is installed on the connecting rod 8 of the screw slide module 7 through the two first mounting nuts 903 on the first force sensor 904.

[0042] The tension adjustment mechanism is located on the left side of the wire arrangement and correction mechanism. The tension swing arm servo motor 13 is fixed to the frame plate 14 of the wire storage chamber of the multi-wire cutting machine by bolts. The inner ring of the bearing of one of the wire arrangement guide wheels 11 of the wire arrangement guide wheel group 9 is mounted on the tension swing arm 12. The tension swing arm 12 is fixed to the motor shaft by screws, and one of the wire arrangement guide wheels 11 is located on the same horizontal line as the head end wire arrangement guide wheel 902.

[0043] The remaining guide wheel in the cable guide wheel assembly 9 is the guide wheel 15, which is fixed to the upper left of the take-up and pay-off roller mechanism. The tension monitoring mechanism 16 is located in a vertical line with the guide wheel 15 and directly below it. The tail cable guide wheel 1602 of the cable guide wheel assembly 9 is mounted on the head of the second force sensor 1605 via the tail cable guide wheel mounting cover 1601. The tension monitoring mechanism 16 is mounted on the fixing base 1604 and fixed to the frame plate via two second mounting nuts 1603 on the second force sensor 1605. The connecting rod 17 is equipped with a wire pulley 18 and is fixed to the far left of the frame plate 14. The wire groove of the wire pulley 18 is tangential to the wire groove of the tail cable guide wheel 1602.

[0044] The diamond cutting wire 10 is led out from the reel-and-wind roller 5, wound onto the head wire guide wheel 902 on the wire arrangement and deviation correction mechanism, and then horizontally connected to one of the wire guide wheels 11. It is then wound onto the passing wheel 15, led out vertically from the passing wheel 15, and wound into the wire groove of the tail wire guide wheel 1602 of the tension monitoring mechanism 16, and finally led to the wire pulley 18 on the connecting rod 17, completing the cutting wire routing in sequence.

[0045] like Figure 4 Furthermore, in the above technical solution, when no offset occurs, the cutting line segment 1001 between the pay-off and take-up roller 5 and the head-end wire guide wheel 902 should be on a vertical line. The cutting line segment 1002 between the head-end wire guide wheel 902 and one of the wire guide wheels 11 on the tension swing arm is horizontal and 90 degrees to the cutting line segment 1001. The cutting line segment 1003 between the passing wheel 15 and the tail-end wire guide wheel 1602 on the tension monitoring mechanism 16 is always on a vertical line. The cutting line segment 1004 between the wire pulley 18 on the connecting rod 17 and the tail-end wire guide wheel 1602 on the tension monitoring mechanism 16 is on a horizontal line and always 90 degrees to the cutting line segment 1003.

[0046] In this embodiment, the automatic deviation correction system of the multi-wire saw includes a PLC controller, and the first force sensor 904, the second force sensor 1605, and the servo motor are electrically connected to the PLC controller via a field bus.

[0047] A method for automatically correcting the deviation of a multi-wire cutting machine includes the following steps:

[0048] (1) The tension swing arm servo motor 13 on the tension adjustment mechanism drives the tension swing arm 12 by giving a given torque to drive the diamond cutting wire on the wire guide wheel assembly 9, so that the diamond cutting wire reaches the preset tension;

[0049] (2) The first force sensor 904 installed on the wire arrangement and correction mechanism and the second force sensor 1605 installed on the tension monitoring mechanism 16 collect the force values ​​of the cutting wire on the corresponding wire arrangement guide wheel;

[0050] (3) The PLC controller determines whether the diamond cutting wire on the wire guide wheel is deflected forward or backward by comparing the values ​​collected by the two force sensors;

[0051] (4) The correction amount of the correction device is obtained based on the difference between the values ​​collected by the two force sensors.

[0052] Among them, the force sensor in step (2) is a cutting line with a preset tension that applies a force to the wire guide wheel, causing the strain material on the force sensor to deform under the force and collect the force value of the cutting line.

[0053] The value collected by the force sensor in step (3) is transmitted to the PLC controller via the field bus.

[0054] The correction amount in step (4) is used as the correction amount of the driving motor of the correction device, and the PLC sends the corrected instruction to the driving motor of the correction device through the bus.

[0055] The specific working process of the automatic deviation correction method of the cable arrangement of the present invention is as follows:

[0056] When the equipment is running, the tension swing arm servo motor 13 gives a torque according to the set tension value to drive the tension swing arm 12 to drive the diamond cutting wire 10 on one of the wire guide wheels 11, so that the diamond cutting wire has a certain tension. The actual tension value of the cutting wire is recorded as F 实际 The servo motor 1 for the reel drives the reel to rotate forward or reverse, retracting or releasing the diamond cutting wire 10 on it. At the same time, the wire arrangement servo motor 6 drives the screw slide module 7 to make the connecting rod 8 on it move back and forth linearly to the left or right, driving the wire arrangement guide wheel 902 installed at the head end of the connecting rod 8, so that the diamond cutting wire can be arranged on the reel or released one circle at a time. The first force sensor 904 installed on the wire arrangement and correction mechanism and the second force sensor 1605 installed on the tension monitoring mechanism 16 collect the respective cutting wire force values ​​F in real time. 排线 、F 监测 The cutting lines at both ends of the tail wire guide wheel 1602 on the tension monitoring mechanism 16 are 90 degrees, so the collected value of the second force sensor 1605 should be The cutting lines at both ends of the first end wire guide wheel 902 are as follows Figure 4 In an ideal state, it is also 90°, and the value collected by the first force sensor 904 should also be

[0057] Due to the error, the cutting line segment 1001 cannot be absolutely vertical, and Figure 5 、 6 At this time, the force F acting on the wire guide wheel by the cutting wire measured by the first force sensor 904 installed on the wire arrangement and correction mechanism is 排线 Will change due to the angle change, in the PLC controller F 排线 With F 监测 For comparison, when F 排线 >F 监测 , the cable guide wheel assembly is offset to the right Figure 5 The situation shown; when F 排线 <F 监测 , the cable guide wheel assembly is offset to the left. Figure 6During the operation of the equipment, the actual tension of the cutting line can be actually collected and converted by the second force sensor 1605 on the tension monitoring mechanism 16, and its value like Figure 5 、 6 As shown, the actual force F exerted by cutting the wires at both ends of the wire guide wheel on the wire guide wheel 18 is 排线 The actual tension F of the cutting line 实际 The angle between them is recorded as θ, and the angle between the cutting line segment 1001 and the axis of the take-up and pay-off roller is 2θ, which can be obtained by the formula The vertical distance H between the arranging guide wheel and the axis of the take-up and pay-off roller is determined after the equipment is installed and is known. Therefore, the required correction amount X of the arranging guide wheel can be calculated. Let the correction to the left be positive and the correction to the right be negative, and we can get The PLC controller sends the calculated correction amount X to the cable servo motor 6 through the field bus. The cable servo motor 6 drives the screw slide module 7 to complete the position adjustment of the cable guide wheel group 9 to achieve automatic correction of the cable.

[0058] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. An automatic wire deviation correction device for a multi-wire cutting machine, characterized in that: It includes a PLC controller and a pay-off and take-up roller mechanism connected to the PLC controller, a wire arrangement and deviation correction mechanism, a tension adjustment mechanism, and a tension monitoring mechanism; The retractable roller mechanism is used for reciprocating cutting line routing; the wire arrangement and correction mechanism includes a correction device and a wire arrangement guide wheel assembly, the wire arrangement guide wheel assembly is used for cutting line routing; the wire arrangement guide wheel at the head end of the wire arrangement guide wheel assembly is driven by the correction device to move along the cutting line routing direction; The head end wire guide wheel includes a first force sensor; the tension monitoring mechanism includes a second force sensor, and the second force sensor is arranged on the tail end wire guide wheel in the wire guide wheel assembly; The difference between the force sensed by the first force sensor and the second force sensor is used as the movement amount of the correction device; The tension adjustment mechanism acts on the wire guide wheel assembly to make the cutting wire reach a preset tension.

2. The automatic wire deviation correction device for a multi-wire cutting machine according to claim 1, characterized in that: The tension adjustment mechanism includes a tension swing arm; one of the wire guide wheels excluding the first and last wire guide wheels in the wire guide wheel group is fixed to the tension swing arm; The tension swing arm drives one of the wire wheels to swing left and right, so that the cutting line reaches a preset tension.

3. The automatic wire deviation correction device for a multi-wire cutting machine according to claim 2, characterized in that: One of the wire pulleys arranged on the tension swing arm is the second wire pulley located behind the tail end wire guide pulley.

4. The automatic wire deviation correction device for a multi-wire cutting machine according to claim 1, characterized in that: The PLC controller is connected to the first force sensor and the second force sensor to collect force sensing values ​​of the first force sensor and the second force sensor in real time.

5. The automatic wire deviation correction device for a multi-wire cutting machine according to claim 1, characterized in that: The correction device is a screw slide module, which includes a drive motor, a connecting rod and a slide, and the head end wire guide wheel is fixed on the connecting rod; The driving motor drives the connecting rod to move along the length direction of the slide, so that the head-end wire guide wheel has a movement amount.

6. The automatic wire deviation correction device for a multi-wire cutting machine according to claim 1, characterized in that: The line arrangement and correction mechanism is located above the wire taking-up and unwinding roller mechanism, and the correction device, the tension adjustment mechanism, and the tension monitoring mechanism are sequentially arranged along the cutting line routing direction.

7. The automatic wire deviation correction device for a multi-wire cutting machine according to claim 1, characterized in that: The wire guide wheel of the wire guide wheel assembly has a winding portion; the winding portions of the corresponding wire guide wheels are installed on the heads of the first force sensor and the second force sensor.

8. A method for automatically correcting the deviation of wire arrangement of a multi-wire cutting machine, characterized in that; The automatic wire deviation correction device according to any one of claims 1 to 7 is used; the automatic wire deviation correction method comprises the following steps: Step 1: After the device is started, the tension adjustment mechanism acts on the wire guide wheel assembly with a given torque, driving the cutting wire on the wire guide wheel assembly to make the cutting wire reach a preset tension; Step 2: The PLC controller collects the force value of the cutting line acting on the wire guide wheel corresponding to the wire guide wheel assembly in real time through the first force sensor and the second force sensor; Step 3: The PLC controller determines the offset direction of the wire on the wire guide wheel based on the collected force value and the set value; In step 4, the PLC controller uses the difference in force between the first force sensor and the second force sensor as the correction movement amount of the correction device.

9. The automatic deviation correction method for a multi-wire cutting machine according to claim 8, characterized in that: In step 2, the force value collected by the first force sensor or the second force sensor is the force exerted by the cutting wire with preset tension on its corresponding wire guide wheel.

10. The automatic deviation correction method for a multi-wire cutting machine according to claim 8, characterized in that: In step 4, the deviation-correcting device includes a driving motor; the deviation-correcting device is a correction value of the driving motor.

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