Diamond wire saw winding machine and wire arrangement detection method

Abstract

The application discloses a diamond wire saw winding machine and a wire arrangement detection method. The diamond wire saw winding machine comprises a winding mechanism, a position detection unit, a number of turns detection unit and a control unit. The winding mechanism is used for rotating to wind and unwind the diamond wire saw. The position detection unit is used for detecting the position of the diamond wire saw on the winding mechanism. The number of turns detection unit is used for detecting the number of turns of the winding mechanism. The control unit is used for controlling the feedback data of the position detection unit and the number of turns detection unit respectively, and obtaining the wire arrangement spacing of the diamond wire saw on the winding mechanism according to the data. The control unit is connected with the position detection unit and the number of turns detection unit, the number of turns in the wire arrangement period of the winding mechanism is counted, the wire arrangement spacing in the wire arrangement period is calculated according to the wire arrangement width of the winding mechanism in the wire arrangement period, and the wire arrangement spacing detection is realized. The application has the advantages of simple structure, flexible installation, real-time online detection and quality detection after production.

Description

Technical Field

[0001] This application belongs to the field of diamond wire production technology, specifically relating to a diamond wire saw winding machine and a wire routing detection method. Background Technology

[0002] Diamond wire sawing technology has become the mainstream technology for silicon material cutting in the photovoltaic industry due to its advantages such as high efficiency and low loss. Diamond wire production generally involves three processes: mother wire, semi-finished product, and finished product. The semi-finished diamond wire usually needs to undergo rewinding and sharpening processes to become finished diamond wire. The rewinding process can adapt to the product requirements of different customers. During the rewinding process, the quality of the diamond wire arrangement on the I-beam has a significant impact on the product quality. During the winding process, the diamond wire saw can set the initial wire spacing, and the winding machine winds the wire according to the set spacing to achieve the expected winding requirements.

[0003] However, in the current diamond wire winding production process, it is impossible to detect whether there are errors in the wire winding. Summary of the Invention

[0004] Purpose of the invention: This application provides a diamond wire saw winding machine to solve the problem that existing diamond wire winding and take-up devices cannot detect the actual wire spacing; another purpose of this application is to provide a diamond wire saw wire winding detection method.

[0005] Technical solution: The diamond wire saw winding machine described in this application includes:

[0006] A winding mechanism is used to rotate and retract the diamond wire saw.

[0007] A position detection unit is used to detect the position of the diamond wire saw on the winding mechanism;

[0008] A rotation detection unit is used to detect the number of rotations of the winding mechanism;

[0009] The control unit is used to control the feedback data of the position detection unit and the number of turns detection unit respectively, and to obtain the wire spacing of the diamond wire saw on the winding mechanism based on the data.

[0010] In some embodiments, the winding mechanism includes a take-up reel having a take-up side, the take-up reel being used to take up the diamond wire saw from the take-up side;

[0011] The position detection unit includes a take-up position detection module, which is located on the take-up side and is used to detect the position of the diamond wire saw on the take-up reel.

[0012] The number of rotations detection unit includes a first number of rotations detection module, which is disposed on the take-up reel and is used to detect the number of rotations of the take-up reel;

[0013] The control unit controls the take-up position detection module and the first turn detection module to feed back take-up data, and obtains the take-up spacing of the diamond wire saw on the take-up reel based on the take-up data.

[0014] In some embodiments, it also includes:

[0015] A take-up and cable-laying screw is provided on the take-up side; the take-up and cable-laying screw includes a screw nut and a screw rod, and the screw nut is slidably provided on the screw rod;

[0016] The cable take-up position detection module includes:

[0017] A first detection probe is located on one side of the lead screw;

[0018] A position recognition component is disposed on the lead screw nut and moves on the lead screw along with the lead screw nut. The position recognition component is used to trigger the detection signal of the take-up position detection module.

[0019] In some embodiments, the winding mechanism includes a wire feeding reel having a wire feeding side for unwinding the diamond wire saw from the wire feeding side;

[0020] The position detection unit includes a wire feeding position detection module, which is located on the wire feeding side and is used to detect the position of the diamond wire saw on the wire feeding wheel.

[0021] The number of rotations detection unit includes a second number of rotations detection module, which is disposed on the pay-off reel and is used to detect the number of rotations of the pay-off reel;

[0022] The control unit controls the wire feeding position detection module and the second turn detection module to feed back wire feeding data, and obtains the wire feeding spacing of the diamond wire saw on the wire feeding wheel based on the wire feeding data.

[0023] In some embodiments, the line-laying position detection module includes:

[0024] The fixing base is fixed to the wire feeding side;

[0025] The second detection probe is connected to the fixed base and is located on the side of the wire feeding reel. The diamond wire saw is in contact with the second detection probe when it is located on the side of the wire feeding reel close to the second detection probe.

[0026] In some embodiments, the position detection unit uses a rising edge triggering and filtering method to acquire signals.

[0027] In some embodiments, a display unit is further included, which is connected to the control unit; the display unit is used to display the number of turns counted by the turn detection unit and the wire spacing curve on the winding mechanism.

[0028] In some embodiments, the winding mechanism has a wire width of l mm, the number of turns of the double-layer wire in the winding mechanism is m turns, and the wire spacing is d mm, satisfying: d = 2l / m.

[0029] Accordingly, this application also provides a method for detecting the wiring of a diamond wire saw, including:

[0030] The position information of the diamond wire saw on the winding mechanism is detected by the position detection unit to obtain the wire laying cycle.

[0031] The number of rotations of the winding mechanism within the winding cycle is detected by the rotation count detection unit;

[0032] The control unit controls the position detection unit and the number of turns detection unit to feed back data within the winding cycle, and obtains the wire spacing of the diamond wire saw on the winding mechanism based on the data.

[0033] In some embodiments, a method for determining whether the ribbon cable is abnormal is also included:

[0034] Determine if the cable spacing in the current cable routing cycle is equal to that in the previous cycle. If they are equal, the cable routing is normal; otherwise, the cable routing is abnormal.

[0035] By statistically analyzing the cable spacing of all cable routing cycles and forming a cable spacing curve, a preset cable spacing threshold range is established. The fluctuation range of the cable spacing curve is then determined to be within the threshold range. If the fluctuation range is within the threshold range, the cable routing is normal; if the fluctuation range exceeds the threshold range, the cable routing is abnormal.

[0036] Beneficial Effects: Compared with the prior art, the diamond wire saw winding machine of this application embodiment includes a winding mechanism, a position detection unit, a number of turns detection unit, and a control unit. The winding mechanism is used to rotate to wind and unwind the diamond wire saw; the position detection unit is used to detect the position of the diamond wire saw on the winding mechanism; the number of turns detection unit is used to detect the number of turns of the winding mechanism; the control unit is used to control the position detection unit and the number of turns detection unit to feed back data, and obtain the wire spacing of the diamond wire saw on the winding mechanism based on the data. This application realizes the counting of turns within the winding cycle by setting the control unit to connect the position detection unit and the number of turns detection unit, and then calculates the wire spacing within the winding cycle using the wire width of the winding mechanism within the winding cycle, thereby realizing the detection of wire spacing. This application has a simple structure, can be flexibly installed, and can realize real-time online detection and quality inspection after production.

[0037] Compared with existing technologies, this application provides a diamond wire saw wire layout detection method, which includes: detecting the position information of the diamond wire saw on the winding mechanism through a position detection unit to obtain the wire layout cycle; detecting the number of rotations of the winding mechanism within the wire layout cycle through a rotation count detection unit; controlling the position detection unit and the rotation count detection unit to feed back data within the wire layout cycle through a control unit, and obtaining the wire layout spacing of the diamond wire saw on the winding mechanism based on the data. This application calculates the wire layout spacing by statistically analyzing the number of rotations of the take-up I-beam winding mechanism within the wire layout cycle and combining it with the wire layout width within the wire layout cycle. This method can detect the wire layout spacing in real time, and is simple, convenient, and highly accurate. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a schematic diagram of the structure of a diamond wire saw winding machine according to an embodiment of this application;

[0040] Figure 2 This is a schematic diagram of the cable take-up and cabling detection working status according to an embodiment of this application;

[0041] Figure 3 This is a schematic diagram of the cable laying and wiring detection working state according to an embodiment of this application;

[0042] Figure 4 This is a flowchart of the ribbon cable detection method according to an embodiment of this application;

[0043] Figure 5This is a flowchart of the cable take-up and cabling detection method according to an embodiment of this application;

[0044] Figure 6 This is a flowchart of the wiring and cabling detection method according to an embodiment of this application.

[0045] Figure label:

[0046] 1. Winding mechanism; 11. Take-up reel; 111. Take-up side; 112. First side; 113. Second side; 114. Take-up shaft; 12. Pay-off reel; 121. Pay-off side; 122. Third side; 123. Fourth side; 124. Pay-off shaft; 2. Position detection unit; 21. Take-up position detection module; 211. First detection probe; 212. Position identification component; 22. Pay-off position detection module; 221. Second detection probe; 222. Fixing base; 3. Turns detection unit; 31. First turns detection module; 32. Second turns detection module; 4. Control unit; 5. Display unit; 6. Diamond wire saw; 7. Take-up and wire-laying screw; 71. Screw nut; 72. Lead screw. Detailed Implementation

[0047] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0048] In the description of this application, it should be understood that the terms "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, and "at least one" can mean one, two, or more, unless otherwise explicitly specified. In the description of this application, "perpendicular" means completely perpendicular to 90° or almost completely perpendicular, for example, the range of included angles from 80° to 100° is considered perpendicular. Similarly, "parallel" means completely parallel or almost completely parallel, for example, the range of completely parallel angles from 10° is considered parallel.

[0049] Please refer to the following: Figure 1 and Figure 2 This application provides a diamond wire saw winding machine, which is installed inside the winding machine. The winding includes a winding mechanism 1, a position detection unit 2, a number of turns detection unit 3, and a control unit 4. The winding mechanism 1 is used to rotate to wind and unwind the diamond wire saw 6. The position detection unit 2 is used to detect the position of the diamond wire saw 6 on the winding mechanism 1. The number of turns detection unit 3 is used to detect the number of turns of the winding mechanism 1. The control unit 4 is used to control the feedback data of the position detection unit 2 and the number of turns detection unit 3 respectively, and is used to receive and obtain the wire spacing of the diamond wire saw 6 on the winding mechanism 1 based on the feedback data of the position detection unit 2 and the number of turns detection unit 3.

[0050] In this embodiment, a position detection unit 2 is provided on the side of the winding mechanism 1, and a diamond wire saw 6 repeatedly passes through the position detection unit 2 to determine one winding cycle. A number of turns detection unit 3 is provided on the winding mechanism 1 to detect the number of rotations of the winding mechanism 1. The control unit 4 is used to count the number of turns and calculate the wire spacing.

[0051] This application achieves the counting of turns of the winding mechanism 1 within one winding cycle by setting up a control unit 4 to connect the position detection unit 2 and the number of turns detection unit 3. Then, it calculates the winding spacing within the winding cycle using the width of the I-beam wheel to achieve winding spacing detection. This application has a simple structure, can be flexibly installed, and can realize real-time online detection and quality inspection after production.

[0052] In some embodiments, the winding mechanism 1 includes a take-up reel 11, which has a take-up side 111 for taking up the diamond wire saw 6 from the take-up side 111. The take-up reel 11 also includes opposing first sides 112 and second sides 113, which limit the laying of wire, restricting the laying of wire to only between the first sides 112 and the second sides 113. The width of the take-up reel 11, i.e., the laying width, is the width between the first sides 112 and the second sides 113. Distance; the take-up position detection module 21 is located on the take-up side 111 and is used to detect the position of the diamond wire saw 6 on the take-up reel 11; the number of turns detection unit 3 includes a first number of turns detection module 31, which is set on the take-up reel 11 and is used to detect the number of turns of the take-up reel 11; the control unit 4 controls the take-up position detection module 21 and the first number of turns detection module 31 to feed back take-up data, and obtains the take-up spacing of the diamond wire saw 6 on the take-up reel 11 based on the take-up data.

[0053] Specifically, in this embodiment, when detecting the wire layup spacing, the control unit 4, the take-up position detection module 21, and the first turn detection module 31 are all in the active state. Simultaneously, when the diamond wire saw 6 first passes the take-up position detection module 21, the first turn detection module 31 begins counting the number of turns. Then, when the diamond wire saw 6 passes the take-up position detection module 21 for the second time, the counting continues, and the counting stops when the diamond wire saw 6 passes the take-up position detection module 21 for the third time. At this point, the diamond wire saw 6 has wound two layers on the take-up reel 11, which is equivalent to the diamond wire saw 6 laying wire across the width of two take-up reels 11. By dividing twice the width of the take-up reel 11 by the number of turns counted by the first turn detection module 31, the wire layup spacing for that wire layup cycle is obtained, thus achieving the wire layup detection for that wire layup cycle.

[0054] In some embodiments, the diamond wire saw winding machine further includes a take-up lead screw 7, which is disposed on the take-up side 111; the take-up lead screw 7 includes a lead screw nut 71 and a lead screw 72, the lead screw nut 71 being slidably disposed on the lead screw 72; the take-up position detection module 21 includes: a first detection probe 211, the first detection probe 211 being located on one side of the lead screw 72; and a position recognition component 212, disposed on the lead screw nut 71 and moving with the lead screw nut 71 on the lead screw 72, the position recognition component 212 being used to trigger the detection signal of the take-up position detection module 21.

[0055] It should be noted that the diamond wire saw winding machine typically also includes a take-up and wire-laying screw 7. The take-up and wire-laying screw 7 includes a screw nut 71 and a lead screw 72. The diamond wire saw 6 is positioned on the screw nut 71, and the screw nut 71 slides on the lead screw 72 to position the diamond wire saw 6. Additionally, the take-up position detection module 21 includes a first detection probe 211 and a position recognition component 212. The first detection probe 211 is located on the side of the take-up and wire-laying screw 7, and the corresponding position recognition component 212 is located on the screw nut 71. The first detection probe 211 and the position recognition component 212 work together, functioning as a switch to turn the first turn detection module 31 on and off.

[0056] It should also be noted that the position recognition component 212 reciprocates on the take-up and wire-laying screw 7 along with the lead screw nut 71. When the position recognition component 212 moves to the vicinity of the first detection probe 211, the first detection probe 211 detects the position recognition component 212. Correspondingly, the diamond wire saw 6 is also located near the first detection probe 211 at this time. When the first detection probe 211 detects the position recognition component 212 again, the diamond wire saw 6 reaches the same position once more. Therefore, by using the cooperation of the first detection probe 211 and the position recognition component 212, the take-up and wire-laying cycle of the diamond wire saw 6 can be controlled.

[0057] Specifically, when the first detection probe 211 first senses the position recognition component 212, it transmits this information to the control unit 4. The control unit 4 then controls the first rotation count detection module 31 to start working and begin counting the rotations. Taking the diamond wire saw 6 first laying the wire towards the first side 112 as an example, when the first detection probe 211 senses the position recognition component 212 for the second time, it is equivalent to the wire laying having undergone double-layer winding from the position opposite the take-up reel 11 to one side of the take-up reel 11, but the take-up reel 11 has not yet started winding from that position to the other side. Therefore, the winding continues, and the number of turns continues to be counted. When the first detection probe 211 senses the position recognition component 212 for the third time, the take-up reel 11 has completed the double-layer winding of the other half. When they are combined, it is equivalent to the diamond wire saw 6 completing the double-layer winding from the initial counting point of the take-up reel 11 to the first side 112, then from the first side 112 to the second side 113, and then from the second side 113 back to the initial counting point. At this time, the count of turns is stopped. The winding spacing within this winding cycle is obtained by dividing the width of the take-up reel 11 by the count of turns.

[0058] It should be noted that the take-up position detection module 21 and the first turn count detection module 31 can be applied in a normal diamond wire saw 6 production line to detect the take-up and wire laying spacing of the diamond wire saw 6 in real time, and can also be used for wire laying detection after diamond winding is completed. At this time, the I-beam reel of the diamond wire saw 6 after take-up is placed on the wire feeding station of the winding machine, and another I-beam reel is taken as the take-up reel 11, and the take-up and wire laying detection can be performed.

[0059] like Figure 1 and Figure 3 As shown, in some embodiments, the winding mechanism 1 includes a wire feeding wheel 12, which has a wire feeding side 121 and is used to unwind the diamond wire saw 6 from the wire feeding side 121; the position detection unit 2 includes a wire feeding position detection module 22, which is located on the wire feeding side 121 and is used to detect the position of the diamond wire saw 6 on the wire feeding wheel 12; the number of turns detection unit 3 includes a second number of turns detection module 32, which is disposed on the wire feeding wheel 12 and is used to detect the number of turns of the wire feeding wheel 12; the control unit 4 controls the wire feeding position detection module 22 and the second number of turns detection module 32 to feed back wire feeding data, and obtains the wire feeding spacing of the diamond wire saw 6 on the wire feeding wheel 12 based on the wire feeding data.

[0060] In this embodiment of the application, the winding machine can also be equipped with a wire feeding position detection module 22 and a second turn detection module 32 at the wire feeding wheel 12 to detect the wire feeding and arrangement on the wire feeding wheel 12. Thus, the wire spacing of the diamond wire saw 6 after winding can also be detected by the wire feeding method.

[0061] Specifically, the wire feeding position detection module 22 is set on the wire feeding side 121 of the wire feeding reel 12. The wire feeding reel 12 includes a third side 122 and a fourth side 123, which are opposite each other. The wire feeding position detection module 22 is set close to the third side 122 or close to the fourth side 123. In this embodiment, it is set close to the third side. Specifically, it is adjusted so that when the diamond wire saw 6 is released from the third side 122, the diamond wire saw 6 contacts the wire feeding position detection module 22. The second rotation count detection module 32 is set on the wire feeding shaft 124 corresponding to the wire feeding reel 12. At this time, the control unit 4, the second rotation count detection module 32 and the wire feeding position detection module 22 are turned on. When the diamond wire saw 6 first contacts the wire feeding position detection module 22, i.e., when it is located on the third side 122, the second rotation detection module 32 starts counting, and the wire feeding wheel 12 starts feeding wire. When the diamond wire saw 6 contacts the wire feeding position detection module 22 for the second time, the second rotation detection stops counting. At this time, the diamond wire saw 6 has gone through the movement process from the third side 122 to the fourth side 123, and then from the fourth side 123 back to the third side 122. The diamond wire saw 6 has completed double-layer wire feeding. At this time, the wire feeding distance in one wire feeding cycle can be obtained by dividing twice the width of the wire feeding wheel 12 by the number of rotations of the wire feeding shaft 124.

[0062] In some embodiments, the wire feeding position detection module 22 includes a fixed base 222 and a second detection probe 221. The fixed base 222 is fixed to the wire feeding side 121, and the second detection probe 221 is connected to the fixed base 222. The second detection probe 221 is located on the side of the wire feeding reel 12. When the diamond wire saw 6 is located on the side of the wire feeding reel 12 near the second detection probe 221, it contacts the second detection probe 221.

[0063] Specifically, the second detection probe 221 is used to detect the position of the diamond wire saw 6 when the wire feeding reel 12 feeds the wire, and the second detection probe 221 determines the position by contacting the diamond wire saw 6.

[0064] It should be noted that in this application, the second detection probe 221 is set on the third side 122 of the wire feeding reel 12, specifically at the position when the diamond wire saw 6 is feeding wire at its outermost position. At this time, the second detection probe 221 is in contact with the diamond wire saw 6. As the diamond wire saw 6 gradually feeds wire from the outside to the inside, the diamond wire saw 6 gradually moves away from the second detection probe 221. Setting the second detection probe 221 on the outside can ensure position detection while avoiding the second detection probe 221 from obstructing the normal wire feeding of the diamond wire saw 6.

[0065] In some embodiments, both the first revolution detection module 31 and the second revolution detection module 32 include encoders, and the control unit 4 includes a counter. The control unit 4 acquires the position of the encoder through the counter.

[0066] It should be noted that both the first rotation detection module 31 and the second rotation detection module 32 in this application can be encoders, preferably high-precision encoders, which are equivalent to sensors. They generate pulse signals to quickly and accurately reflect the rotational changes of the shaft. The control unit 4 in this application also includes a programmable controller. The programmable controller is connected to the encoder through a high-speed counter and can read and count pulses in real time, thereby realizing the rapid and accurate counting of the rotational rotations of the pay-off shaft 124 and the take-up shaft 114.

[0067] It should also be noted that the first loop detection module 31 and the second loop detection module 32 of this application can be the same loop detection module. Specifically, when it is necessary to perform take-up and lay-up detection, the loop detection module is set on the take-up shaft 114, and when it is necessary to perform lay-up and lay-up detection, the loop detection module is set on the lay-up shaft 124.

[0068] In some embodiments, the take-up position detection module 21 and the release position detection module 22 use a rising edge triggering and filtering method to acquire signals.

[0069] It should be noted that, by employing a rising edge triggering method and incorporating filtering functionality, the take-up position detection module 21 and the release position detection module 22 can more reliably acquire position signals and perform position detection and control in a more accurate manner. This design can reduce the impact of noise on the system and improve the accuracy and reliability of position detection.

[0070] It should also be noted that the filtering in this embodiment is preferably 50 milliseconds. This 50-millisecond delay can eliminate brief interference signals, retaining only valid signals lasting longer than 50 milliseconds. This improves the stability and accuracy of signal acquisition.

[0071] In some embodiments, a display unit 5 is also included, which is electrically connected to the control unit 4. The display unit 5 is used to display the number of turns counted by the first turn count detection module 31 and the wire spacing curve on the take-up reel 11, or the number of turns counted by the second turn count detection module 32 and the wire spacing curve on the pay-off reel 12.

[0072] This application, by setting up a display unit 5, allows for the setting of detection commands for take-up and release wire laying detection. Furthermore, the display unit 5 can display the number of loops in one laying cycle as counted by the first loop detection module 31 or the second loop detection module 32, as well as the cumulative number of loops in all laying cycles for both take-up and release wire laying detection. It also records the spacing of the previous laying cycle, facilitating comparison between the spacing of the current laying cycle and the spacing of the previous laying cycle. Additionally, it can display the spacing of all laying cycles as a curve on the time axis, making it easy to observe when a laying abnormality occurs.

[0073] In some embodiments, the winding mechanism 1 has a wire width of l mm, the number of turns of the double-layer wire in the winding mechanism 1 is m turns, and the wire spacing is d mm, satisfying: d = 2l / m.

[0074] It should be noted that this application uses the position detection unit 2 to detect that the diamond wire saw 6 repeatedly passes through the same position to form a wire laying cycle. Within this cycle, the diamond wire saw repeatedly lays or releases two layers of wire. Therefore, the total wire laying width in this cycle is twice the wire laying width of the winding mechanism. Since the winding mechanism 1 is an I-beam wheel, the total wire laying width is the width of two layers of the I-beam wheel. Simultaneously, by statistically analyzing the number of rotations of the winding mechanism 1 within a single cycle, the total wire laying width is divided by the number of rotations to obtain the corresponding wire laying spacing. This method is simple to calculate and can obtain the average wire laying spacing within a single wire laying cycle. In actual production, by comparing the wire laying spacing of multiple identical wire laying cycles, it is possible to determine whether there are any abnormalities in the wire laying.

[0075] like Figure 4 As shown in the embodiment of this application, a diamond wire saw wire routing detection method detects the position information of the diamond wire saw 6 on the winding mechanism 1 through the position detection unit 2; detects the number of rotations of the winding mechanism 1 through the number of rotations detection unit 3; controls the position detection unit 2 and the number of rotations detection unit 3 to feed back data through the control unit 4, and obtains the wire routing spacing of the diamond wire saw 6 on the winding mechanism 1 based on the data.

[0076] This application embodiment calculates the wire spacing by combining the number of rotations of the take-up I-beam winding mechanism within the wire laying cycle with the wire laying width within that cycle. This allows for real-time detection of the wire spacing and is simple, convenient, and highly accurate.

[0077] like Figure 5 As shown, the cable detection method in this application embodiment further includes detection of the cable take-up spacing.

[0078] The position information of the diamond wire saw 6 on the take-up reel 11 of the winding mechanism 1 is first detected by the take-up position detection module 21 of the position detection unit 2, and the number of rotations of the take-up reel 11 is detected by the first rotation number detection module 31 of the rotation number detection unit 3.

[0079] The position information of the diamond wire saw 6 on the take-up reel 11 is detected for the second time by the take-up position detection module 21, and the first rotation count detection module 31 continues to detect the number of rotations of the take-up reel 11.

[0080] The position information of the diamond wire saw 6 on the take-up reel 11 is detected for the third time by the take-up position detection module 21, and the first rotation count detection module 31 stops detecting the number of rotations of the take-up reel 11.

[0081] The control unit 4 obtains the wire take-up spacing of the diamond wire saw 6 on the take-up reel 11 based on the number of turns detected by the first turn detection module 31 when the take-up position detection module 21 detects the diamond wire saw 6 for the third time, combined with the width of the take-up reel 11.

[0082] Specifically, the specific steps for detecting the cable take-up and cabling spacing in this application embodiment are as follows:

[0083] The take-up position detection module 21 is fixed to the take-up side of the take-up reel 11 of the winding machine. The position of the take-up position detection module 21 is adjusted so that the first detection probe 211 is located in the middle position of the take-up lead screw 7. Then, the position recognition component 212 is installed on the lead screw nut 71 to trigger the position detection signal. The first turn count detection module 31 is installed on the take-up shaft 114 of the take-up reel 11. The programmable controller collects the number of turns on the take-up reel 11 through a high-speed counter. After the preparation is completed, the winding machine is started. When the position recognition component 212 senses the first detection probe 211 for the first time, this is taken as the statistical starting point of a wire laying cycle. The programmable controller starts to count the number of turns on the take-up reel 11. The diamond wire saw 6 lays wire from the current position to the side of the take-up reel 11. In this embodiment, the wire is laid to the first side 112 first. That is, when the position recognition component 212 senses the first detection probe 211 for the first time, the diamond wire saw 6 moves from its current position to the first side 112, and after reaching the first side 112, it turns back to continue moving the wire; when the position recognition component 212 senses the first detection probe 211 for the second time, the double-layer wire movement from the position of the first detection probe 211 relative to the take-up reel 11 to the first side 112 is completed, and the take-up and wire movement continues. The programmable controller continues to count the number of turns of the pay-off reel 12. When the diamond wire saw 6 moves the wire to the second side 113, it turns back to continue moving the wire; when the position recognition component 212 senses the first detection probe 211 for the third time, the diamond wire saw 6 moves from its current position to the first side 112, and then ... When the first detection probe 211 is sensed for the first time, it marks the end of a wiring cycle. The programmable controller then counts the number of turns of the take-up reel 11. During this time, the take-up reel 11 completes double-layer wiring from its position relative to the first detection probe 211 to the second side 113 within the time interval between the second and third sensing of the first detection probe 211 by the position recognition component 212. Thus, the take-up reel 11 performs two round trips of winding during the time interval between the first and third sensing of the first detection probe 211 by the position recognition component 212. Therefore, the wiring spacing of the take-up reel 11 is calculated based on twice the width of the take-up reel 11 and the counted number of turns. Simultaneously, the number of turns is reset to zero and recounted as calculation data for the next wiring cycle. The third sensing of the first detection probe 211 by the position recognition component 212 marks the start of the next wiring cycle, equivalent to the first sensing of the first detection probe 211 by the position recognition component 212 for the next wiring cycle.

[0084] like Figure 6 As shown, further, the cabling detection method in this application embodiment includes cabling spacing detection.

[0085] The position information of the diamond wire saw 6 on the wire feeding wheel 12 of the winding mechanism 1 is first detected by the wire feeding position detection module 22 of the position detection unit 2, and the number of rotations of the wire feeding wheel 12 is detected by the second rotation number detection module 32 of the rotation number detection unit 3.

[0086] The position information of the diamond wire saw 6 on the pay-off reel 12 is detected for the second time by the pay-off position detection module 22, and the second rotation count detection module 32 stops detecting the number of rotations of the pay-off reel 12.

[0087] The control unit 4 obtains the wire feeding spacing of the diamond wire saw 6 on the wire feeding wheel 12 based on the number of turns detected by the second number of turns detection module 32 when the wire feeding position detection module 22 detects the diamond wire saw 6 for the second time, combined with the wheel width of the wire feeding wheel 12.

[0088] Specifically, the specific steps for detecting the spacing between the laid-out and laid-out cables in this embodiment are as follows:

[0089] First, install the wire feeding position detection module 22 on the wire feeding side 121 of the wire feeding wheel 12 of the winding machine. Adjust the position of the wire feeding position detection module 22 so that the diamond wire saw 6 can contact the second detection probe 221 of the wire feeding position detection module 22 when the wire is exiting from the third side 122, at which time the position detection signal can be triggered. Then, install the second turn detection module 32 on the wire feeding shaft 124 of the wire feeding wheel 12. The programmable controller collects the number of turns of the wire feeding wheel 12 through the high-speed counter. When the winding machine is started, the first contact between the diamond wire saw 6 and the second detection probe 221 marks the starting point of a winding cycle. The control unit 4 begins counting the number of turns of the pay-off reel 12. At this point, the diamond wire saw 6 is located on the third side 122. The diamond wire saw 6 then gradually pays off wire towards the fourth side 123. After reaching the fourth side 123, it reverses direction and pays off wire towards the third side 122. When the diamond wire saw 6 contacts the second detection probe 221 for the second time, i.e., when the diamond wire saw 6 reaches the third side 122, this marks the end of a winding cycle. The programmable controller then counts the number of turns of the pay-off reel 12. At this point, the pay-off reel 12 has completed two round trips of wire feeding. Therefore, the wire spacing of the pay-off reel 12 is calculated based on twice the width of the pay-off reel 12 and the counted number of turns. Simultaneously, the number of turns is reset to zero and recounted for the next winding cycle. It should be noted that the second contact between the diamond wire saw 6 and the second detection probe 221 at this time serves as the starting point of the next row of wires, which is equivalent to the first contact between the diamond wire saw 6 and the second detection probe 221 in the next row of wires.

[0090] In this embodiment, the wire laying spacing detection can be used to detect the wire laying of the winding take-up reel 11 after winding, thereby detecting whether there are any abnormalities in the early wire laying.

[0091] Furthermore, the take-up position detection module 21 and the first turn detection module 31 of the winding machine in this application are used for take-up and wire arrangement detection, while the release position detection module 22 and the second turn detection module 32 are used for release and wire arrangement detection. Therefore, the winding machine of this application can simultaneously perform release and take-up wire arrangement detection. In this case, the release position detection module 22 is set on the release side 121 of the release wheel 12 at the release station of the winding machine, the second turn detection module 32 is set on the release shaft 124, the take-up position detection module 21 is set on the take-up side 111 of the take-up wheel 11 at the take-up station of the winding machine, and the first turn detection module 31 is set on the take-up shaft 114 of the take-up wheel 11. This allows for simultaneous release and take-up wire arrangement detection. Through simultaneous detection at both ends, data comparison can be performed, resulting in more accurate wire arrangement detection results. Thus, by simultaneously comparing the wire arrangement spacing at both ends to determine if there are differences, abnormal wire arrangement can be intuitively identified.

[0092] In some embodiments, the method further includes a method for determining whether the cabling is abnormal: determining whether the cabling spacing of the current cabling cycle is equal to the cabling spacing of the previous cabling cycle; if they are equal, the cabling is normal; if they are not equal, the cabling is abnormal; or,

[0093] By statistically analyzing the cable spacing of all cable routing cycles and forming a cable spacing curve, a preset cable spacing threshold range is established. The fluctuation range of the cable spacing curve is then determined to be within the threshold range. If the fluctuation range is within the threshold range, the cable routing is normal; if the fluctuation range exceeds the threshold range, the cable routing is abnormal.

[0094] This application can not only detect the wire spacing between the pay-off reel 12 and the take-up reel 11, but also compare the wire spacing in two adjacent wire-laying cycles to determine whether there is any abnormality in the wire spacing of the current wire-laying cycle. This allows for timely detection of wire-laying anomalies through real-time monitoring, enabling appropriate troubleshooting. Furthermore, this application can integrate the wire spacing corresponding to each wire-laying cycle to form a time-wire spacing curve, with a pre-set wire spacing threshold range. If the wire spacing is normal, the fluctuation range of the wire spacing curve is within the threshold range; if the wire spacing is abnormal, the fluctuation range of the wire spacing curve exceeds the threshold range. Simultaneously, this embodiment can display the wire spacing curve through the display unit 5, allowing for intuitive detection of wire spacing anomalies and identification of the time period in which the anomaly occurred.

[0095] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0096] The above provides a detailed description of a diamond wire saw winding machine and testing method provided in the embodiments of this application, and uses specific examples to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the technical solutions and core ideas of this application. Those skilled in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A method for detecting the wiring of a diamond wire saw, characterized in that, The diamond wire saw winding machine is used in a diamond wire saw winding machine. The diamond wire saw winding machine includes: a winding mechanism (1), a position detection unit (2), a number of turns detection unit (3), and a control unit (4). The winding mechanism (1) is used to rotate to wind and unwind the diamond wire saw (6). The cable testing method includes: The position of the diamond wire saw (6) on the winding mechanism (1) is detected by the position detection unit (2) to obtain the wire laying cycle; The number of rotations of the winding mechanism (1) during the winding cycle is detected by the number of rotations detection unit (3); The control unit (4) controls the data within the winding cycle fed back by the position detection unit (2) and the number of turns detection unit (3), and obtains the wire spacing of the diamond wire saw (6) on the winding mechanism (1) based on the data. Determine whether the cable spacing of the current cable routing cycle is equal to that of the previous cable routing cycle. If they are equal, the cable routing is normal; otherwise, the cable routing is abnormal. Alternatively, by statistically analyzing the cable spacing of all cable routing cycles and forming a cable spacing curve, a preset cable spacing threshold range is established. Determine whether the fluctuation range of the cable spacing curve is within the threshold range. If the fluctuation range is within the threshold range, the cable routing is normal; otherwise, the fluctuation range exceeds the threshold range, the cable routing is abnormal.

2. The diamond wire saw wire routing detection method according to claim 1, characterized in that, The winding mechanism (1) includes a take-up reel (11) having a take-up side (111) for taking up the diamond wire saw (6) from the take-up side (111). The position detection unit (2) includes a take-up position detection module (21), which is located on the take-up side (111) and is used to detect the position of the diamond wire saw (6) on the take-up reel (11). The number of rotations detection unit (3) includes a first number of rotations detection module (31), which is disposed on the take-up reel (11) and is used to detect the number of rotations of the take-up reel (11); The control unit (4) controls the take-up position detection module (21) and the first turn detection module (31) to feed back take-up data, and obtains the take-up spacing of the diamond wire saw (6) on the take-up wheel (11) based on the take-up data.

3. The diamond wire saw wire routing detection method according to claim 2, characterized in that, Also includes: A take-up lead screw (7) is provided on the take-up side (111); the take-up lead screw (7) includes a lead screw nut (71) and a lead screw (72), and the lead screw nut (71) is slidably provided on the lead screw (72); The cable retraction position detection module (21) includes: The first detection probe (211) is located on one side of the lead screw (72); A position recognition component (212) is disposed on the lead screw nut (71) and moves with the lead screw nut (71) on the lead screw (72). The position recognition component (212) is used to trigger the detection signal of the take-up position detection module (21).

4. The method for detecting the wire arrangement of a diamond wire saw according to any one of claims 1-3, characterized in that, The winding mechanism (1) includes a wire feeding wheel (12) having a wire feeding side (121) for unwinding the diamond wire saw (6) from the wire feeding side (121). The position detection unit (2) includes a wire feeding position detection module (22), which is located on the wire feeding side (121) and is used to detect the position of the diamond wire saw (6) on the wire feeding wheel (12); The number of rotations detection unit (3) includes a second number of rotations detection module (32), which is disposed on the pay-off reel (12) and is used to detect the number of rotations of the pay-off reel (12); The control unit (4) controls the wire feeding position detection module (22) and the second turn detection module (32) to feed back wire feeding data, and obtains the wire feeding spacing of the diamond wire saw (6) on the wire feeding wheel (12) based on the wire feeding data.

5. The diamond wire saw wire routing detection method according to claim 4, characterized in that, The line laying position detection module (22) includes: Fixing base (222), the fixing base (222) is fixed on the wire laying side (121); The second detection probe (221) is connected to the fixed base (222). The second detection probe (221) is located on the side of the wire feeding reel (12). The diamond wire saw (6) is in contact with the second detection probe (221) when the wire feeding reel (12) is close to the side of the second detection probe (221).

6. The diamond wire saw wire routing detection method according to claim 1, characterized in that, The position detection unit (2) uses rising edge triggering and filtering to acquire signals.

7. The diamond wire saw wire routing detection method according to claim 1, characterized in that, It also includes a display unit (5), which is connected to the control unit (4); the display unit (5) is used to display the number of turns counted by the turn detection unit (3) and the wire spacing curve on the winding mechanism (1).

8. The diamond wire saw wire routing detection method according to claim 1, characterized in that, The winding mechanism (1) has a wire width of l mm, the number of turns of the double-layer wire of the winding mechanism (1) is m turns, and the wire spacing is d mm, satisfying: d=2l / m.

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