Automatic orientation adjustment method for sawing extruded products

Abstract

A kind of automatic orientation adjustment method of extruded product sawing, sawing machine is connected after feed roller table, a plurality of sensor arrays are arranged on feed roller table, the plurality of sensors of same number and matching position are evenly arranged into linear array by sensor array, linear direction is perpendicular to the direction of travel of feed roller table;The extruded product group passing above feed roller table is detected by sensor, to judge the position state and shape state of extruded product group.The present application has the function of automatically detecting the position and state of extruded metal pipe and bar section, and can distinguish the state of product skew, product bending, batch product not closing, etc., and can adjust the position of product, greatly reduce the defects such as cutting skew, bending product not found processing in sawing process.

Description

Technical Field

[0001] This invention relates to the field of metal processing technology, specifically to an automatic orientation adjustment method for sawing extruded products. Background Technology

[0002] Sawing is an essential step in metal extrusion processing, especially for copper and aluminum extruded tubes and bars. Precise sizing is crucial in the final stage to obtain finished products or transfer them to the next process. During sawing, the length of the metal tube or bar must be perpendicular to the saw blade or band saw to prevent skew cuts, which would result in scrap and reduce the yield rate. However, during sawing, the worker stands at the far end of the tube or bar against the saw table's positioning surface, making it difficult to accurately observe whether the material is parallel and aligned. This is especially true when the material is long and wide, increasing the probability of skew cuts. Furthermore, since metal tubes and bars undergo quenching and stretching after extrusion, errors in these processes can cause insufficient straightness (bending). This results in extruded products being directly mixed with qualified products and shipped out. Third, because products with insufficient straightness are mixed in with batches of metal products, when multiple extruded products are sawn in batches, adjacent products of curved products are affected, resulting in defects such as tilted saw cuts. Summary of the Invention

[0003] The purpose of this invention is to provide an automatic orientation adjustment method for sawing extruded products. This method can automatically detect the position and state of extruded metal tubes and rods, identify conditions such as product skewing, product bending, and batch products not being gathered, and adjust the position of the products, thereby significantly reducing defects such as skewing and failure to detect and process bent products during the sawing process.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows:

[0005] An automatic orientation adjustment method for sawing extruded products includes a saw connected to a feed roller table. Several sensor arrays are installed on the feed roller table, consisting of multiple sensors of the same number and matched positions evenly arranged in a linear array, with the linear direction perpendicular to the travel direction of the feed roller table. The sensors detect the extruded product groups passing above the feed roller table, determining their position and shape. The sensors are diffuse reflection photoelectric sensors, capable of sensing extruded products passing above the feed roller table. When an extruded product enters the sensor's area, the sensor sends a signal to a PLC, indicating the presence of material on the feed roller table in that area. The diffuse reflection photoelectric sensors are linearly fixed to a channel steel, which is then fixed to the feed roller table.

[0006] The sensor array is arranged sequentially in the feeding direction of the feed roller table: sensor array A, sensor array B, and sensor array C. When the traveling extruded product group is sensed by sensors at different positions in the above three arrays, it can be considered that there is a positional tilt deviation in the extruded product group.

[0007] The feeding roller table is evenly distributed with lifting rollers. Several forward synchronous belts are set on one side between the lifting rollers, and several reverse synchronous belts are set on the other side. The ends of the forward and reverse synchronous belts intersect at the center line of the feeding roller table. The extruded product group is aligned and gathered at the intersection.

[0008] If the sensor at the middle of the extruded product group detects the presence of an empty space, it can be assumed that the extruded products in the extruded product group are bent or not retracted.

[0009] The sensor logic is as follows:

[0010] When all sensor signals in sensor array ABC are continuous, it can be assumed that the extruded product group does not have any bending or non-shrinkage.

[0011] When the sensor signal of sensor array ABC is discontinuous, it means that the extruded product is bent or not retracted.

[0012] Under the premise of the second point, the forward synchronous belt and the reverse synchronous belt move in opposite directions, causing the extruded product to retract. The sensor signal of the sensor array ABC is then checked again to see if it is continuous. If the sensor signal of the sensor array ABC is still discontinuous, it is determined that the extruded product is bent. At this time, manual intervention is required to remove the bent extruded product.

[0013] Among them, bending is divided into two cases: longitudinal bending and transverse bending. Both cases will trigger the sensor signal discontinuity of the sensor array ABC. Longitudinal bending will cause no signal due to the bending part being far away from the sensor triggering range.

[0014] A lateral adjustment belt mechanism is set at an adjacent position in the direction of travel of the sensor array C. The lateral adjustment belt mechanism includes a belt bracket. Lifting cylinders are set on two columns of the belt bracket. The lifting cylinders are equipped with a horizontal adjustment timing belt that is perpendicular to the feeding direction of the feed roller table. The adjustment timing belt is driven by a belt servo motor.

[0015] The method for calculating the adjustment distance L of the timing belt is: L = (a + c)b / a; where: a is the vertical distance between the center line of sensor array B and the center line of sensor array C; c is the distance between sensor array C and the center line of the lateral adjustment belt mechanism; b is the difference between the position of the lowest sensor sensed by sensor array B and the position of the lowest sensor sensed by sensor array C.

[0016] The working logic of the lateral adjustment belt mechanism is as follows:

[0017] When the sensor signals of sensor arrays ABC are all continuous, and the difference between the bottom sensor position sensed by sensor array B and the bottom sensor position sensed by sensor array C is 0, it is considered that the extruded product is perpendicular to the sawing direction. Then the lifting roller lifts up and transports the extruded product to the sawing machine, and the length is fixed by the length-fixing mechanism of the discharge roller table before sawing.

[0018] When the sensor signals of sensor arrays ABC are all continuous, and the difference between the bottom sensor position sensed by sensor array B and the bottom sensor position sensed by sensor array C is a positive value (Note: by default, the lower the sensor array is in the diagram, the larger the corresponding value), then the PLC considers the head of the extruded product group to be tilted upwards in the diagram; the timing belt is adjusted by the cylinder to lift upwards, supporting the head of the extruded product group, and the servo motor rotates in the forward direction, driving the timing belt to move a horizontal adjustment distance L through the gearbox, so as to achieve the effect of vertical saw blade position adjustment;

[0019] When the sensor signals of sensor arrays ABC are all continuous, and the difference between the bottom sensor position sensed by sensor array B and the bottom sensor position sensed by sensor array C is negative, the PLC assumes that the head of the extruded product group is tilted downwards in the figure. The timing belt is adjusted by the cylinder to lift the head of the extruded product group, and the servo motor rotates in the opposite direction to drive the timing belt to move a horizontal adjustment distance L through the gearbox, so as to achieve the effect of vertical saw blade position adjustment.

[0020] The distance L of the synchronous belt movement can be preset and calculated through the transmission ratio of the synchronous belt sprocket and the servo motor gearbox.

[0021] The saw is connected to a discharge roller table. A length-fixing mechanism is set on one side of the discharge roller table. A traveling slide rail and a gear rail are installed on the support of the length-fixing mechanism. A traveling gear and gear rail are installed on the length-fixing traveling platform and move on the slide rail by a rail seat driven by a traveling motor. A vertical slide rail is set on the length-fixing traveling platform. A lifting platform moves up and down along the vertical slide rail. A length-fixing plate shaft is hinged to the lifting platform. A worm gear is installed on the length-fixing plate shaft. The worm gear meshes with a worm installed on the lifting platform. The worm is driven by a worm motor. A length-fixing plate is installed on the length-fixing plate shaft and is located above the discharge roller table. The head of the extruded product group is positioned by pressing against the end face of the length-fixing plate.

[0022] The length-fixing mechanism is a suspended length-fixing plate type. When a length-fixing operation is required, the PLC controls the length-fixing traveling platform to move along the slide rail to the predetermined position. The cylinder piston rod extends, lowering the lifting platform to its lowest position. Simultaneously, the worm gear motor drives the worm wheel to rotate, which in turn drives the length-fixing plate shaft to rotate. The length-fixing plate, fixed on the shaft, rotates to its lowest position, and its lower end can rest against the head end of the extruded product, thus completing the length-fixing operation. After sawing is completed, the cylinder piston rod retracts, the lifting platform rises to its highest position, and the worm gear motor drives the worm wheel to rotate, which in turn drives the length-fixing plate shaft to rotate. The length-fixing plate, fixed on the shaft, rotates to its highest position, thus moving the length-fixing plate away from the extruded product, making it easier for the operator to move the extruded product off the production line.

[0023] In addition, the worm gear driven sizing plate utilizes the self-locking characteristics of the worm gear to prevent the sizing plate from having sizing errors after multiple pressings of the extruded products, thus improving the durability of the sizing device.

[0024] 1. This invention uses an array of linear sensors to determine the position and bending state of the extruded product group on the feed roller table. Knowing its position and bending state allows for precise subsequent processing, avoiding situations where the sawing operator is too far away from the material or the material is too long, resulting in inadequate observation and untimely processing. It also prevents situations such as skewed sawing or bent material from being mixed into qualified products.

[0025] 2. This invention achieves the positioning of the tilted extruded product group by setting a lateral adjustment belt mechanism. The lateral adjustment displacement value is accurately calculated by the signal obtained by the linear sensor array, realizing the automatic adjustment effect, avoiding the laborious and time-consuming manual adjustment process, and avoiding the errors caused by manual visual adjustment.

[0026] 3. This invention utilizes the principle of opposing forward and reverse synchronous belts to achieve the gathering operation of extruded product groups, avoiding the traditional manual gathering method; or it can be gathered by pressing against the side wall, avoiding deformation of thin-walled extruded products caused by pressing, thereby improving the yield of extruded products. Attached Figure Description

[0027] Figure 1 This is a process flow diagram of the present invention;

[0028] Figure 2 This is a schematic diagram of the overall main structure of the present invention;

[0029] Figure 3 for Figure 2 A magnified schematic diagram of the structure at point I in the middle;

[0030] Figure 4 for Figure 2 A magnified schematic diagram of the structure at point II in the middle;

[0031] Figure 5 for Figure 2 Schematic diagram of the AA section structure;

[0032] Figure 6 This is a top view of the overall structure of the present invention;

[0033] Figure 7 This is a schematic diagram of the sensor array's external structure.

[0034] Figure 8 The diagram shows the lateral adjustment required by the lateral adjustment belt mechanism to address the tilting of the extruded product group.

[0035] Figure 9 This is a schematic diagram of the transverse bending structure of the extruded product assembly;

[0036] Figure 10 This is a schematic diagram of the longitudinal bending structure of the extruded product group;

[0037] Figure 11 Schematic diagram of the extruded product gathering process;

[0038] The numbers and component names in the diagram are as follows: 11-Forward synchronous belt; 12-Reverse synchronous belt; 2-Feed roller table; 21-Lifting roller; 221-Sensor array A; 222-Sensor array B; 223-Sensor array C; 3-Sawing machine; 4-Discharge roller table; 5-Stabilizing mechanism; 51-Traveling slide rail; 52-Gear rail; 53-Traveling motor; 54-Stabilizing traveling table; 55-Traveling gear; 56-Cylinder; 57-Lifting table; 58-Vertical slide rail; 59-Stabilizing plate shaft; 510-Worm motor; 511-Worm; 512-Worm wheel; 513-Stabilizing plate; 6-Transverse adjustment belt mechanism; 61-Belt bracket; 62-Lifting cylinder; 63-Belt servo motor; 64-Adjusting synchronous belt; 7-Extruded product assembly. Implementation Example 1

[0039] An automatic orientation adjustment method for sawing extruded products is provided, wherein a sawing machine 3 is connected to a feed roller table 2, and a plurality of sensor arrays are set on the feed roller table 2. The sensor array consists of multiple sensors of the same number and matching positions evenly distributed in a linear array, with the linear direction perpendicular to the travel direction of the feed roller table 2. The extruded product group 7 passing above the feed roller table 2 is detected by the sensors to determine the position and shape of the extruded product group 7.

[0040] The sensor array is arranged sequentially in the feeding direction of the feed roller table 2, with sensor array A221, sensor array B222, and sensor array C223. When the traveling extruded product group 7 is sensed by sensors at different positions in the above three arrays, it can be considered that there is a positional tilt deviation in the extruded product group 7.

[0041] The feeding roller table 2 is evenly distributed with lifting rollers 21. Several forward synchronous belts 11 are arranged on one side between the lifting rollers 21, and several reverse synchronous belts 12 are arranged on the other side. The ends of the forward synchronous belts 11 and the reverse synchronous belts 12 intersect at the center line of the feeding roller table 2. The extruded product group 7 is aligned and gathered at the intersection.

[0042] If the sensor at the middle of the extruded product group 7 detects the presence of an empty space, it can be assumed that the extruded products in the extruded product group 7 are bent or not retracted.

[0043] The logic of the sensor is as follows:

[0044] 1) When all sensor signals from the sensor array are continuous, it can be assumed that the extruded product group 7 does not have any bending or non-shrinking issues;

[0045] 2) When the sensor signal of the sensor array is discontinuous, that is, there is a situation where the extruded product is bent or not retracted;

[0046] Under the premise of the second point, the forward synchronous belt 11 and the reverse synchronous belt 12 move in opposite directions, causing the extruded product to retract. The sensor signal of the sensor array is checked again to see if it is continuous. If the sensor signal of the sensor array is still discontinuous, it is determined that the extruded product is bent. At this time, manual intervention is required to remove the bent extruded product.

[0047] A lateral adjustment belt mechanism 6 is provided at an adjacent position in the traveling direction of the sensor array C223. The lateral adjustment belt mechanism 6 includes a belt bracket 61. Lifting cylinders 62 are provided on the two columns of the belt bracket 61. A horizontal adjustment timing belt 64 is installed on the lifting cylinder 62 and its direction is perpendicular to the feeding direction of the feed roller table 2. The adjustment timing belt 64 is driven by a belt servo motor 63.

[0048] The method for calculating the adjustment distance L of the timing belt 64 is: L = (a + c)b / a; where: a is the vertical distance between the center line of sensor array B222 and the center line of sensor array C223; c is the distance between sensor array C223 and the center line of the transverse adjustment belt mechanism 6; b is the difference between the position of the bottommost sensor sensed by sensor array B222 and the position of the bottommost sensor sensed by sensor array C223.

[0049] The working logic of the lateral adjustment belt mechanism is as follows:

[0050] 1) When all sensor signals of the sensor array are continuous, and the difference between the bottom sensor position sensed by sensor array B222 and the bottom sensor position sensed by sensor array C223 is 0, it is considered that the extruded product is perpendicular to the sawing direction. Then the lifting roller lifts up and transports the extruded product to the sawing machine, and the length is fixed by the length-fixing mechanism 5 of the discharge roller table before sawing.

[0051] 2) When all sensor signals of the sensor array are continuous, and the difference between the bottom sensor position sensed by sensor array B222 and the bottom sensor position sensed by sensor array C223 is positive, the PLC assumes that the head of the extruded product group 7 is tilted upwards in the figure; the timing belt is adjusted by the cylinder to lift the head of the extruded product group, and the servo motor rotates in the forward direction to drive the timing belt to move a horizontal adjustment distance L through the gearbox, so as to achieve the effect of vertical saw blade position adjustment;

[0052] 3) When all sensor signals of the sensor array are continuous, and the difference between the lowest sensor position sensed by sensor array B222 and the lowest sensor position sensed by sensor array C223 is negative, the PLC considers that the head of the extruded product group 7 is tilted downwards in the figure; the adjusting synchronous belt is lifted upwards by the lifting cylinder 62 to support the head of the extruded product group 7, and the belt servo motor 63 rotates in the opposite direction to drive the adjusting synchronous belt 64 to move a horizontal adjustment distance L through the gearbox, so as to achieve the effect of adjusting the verticality of the extruded product group 7.

[0053] The sawing machine 3 is connected to the discharge roller table 4. A length-fixing mechanism 5 is set on one side of the discharge roller table 4. The support of the length-fixing mechanism 5 is equipped with a traveling slide rail 51 and a toothed rail 52. A traveling gear 55 is installed on the length-fixing traveling table 54 and meshes with the toothed rail 52. Driven by the traveling motor 53, it travels on the slide rail 51 using a rail seat. A vertical slide rail 58 is set on the length-fixing traveling table 54. A lifting table 57 moves up and down along the vertical slide rail 58. A length-fixing plate shaft 59 is hinged on the lifting table 57. A worm gear 512 is installed on the length-fixing plate shaft 59. The worm gear 512 meshes with a worm 511 installed on the lifting table 57. The worm 511 is driven by a worm motor 510. A length-fixing plate 513 is installed on the length-fixing plate shaft 59. The length-fixing plate 513 is above the discharge roller table 4. The head of the extruded product group 7 is positioned by pressing against the end face of the length-fixing plate 513.

Claims

1. A method for automatic orientation adjustment during sawing of extruded products, characterized in that: The feed roller table (2) is connected to the saw (3). Several sensor arrays are set on the feed roller table (2). The sensor array consists of multiple sensors of the same number and matching positions evenly arranged in a straight line array. The straight line direction is perpendicular to the travel direction of the feed roller table (2). The extruded product group (7) passing above the feed roller table (2) is detected by the sensors to determine the position and shape of the extruded product group (7). The sensor array is arranged sequentially in the feeding direction of the feed roller table (2) as sensor array A (221); sensor array B (222); and sensor array C (223). When the moving extruded product group (7) is sensed by the sensors at different positions in the above three arrays, it can be considered that there is a positional tilt deviation in the extruded product group (7). The feeding roller table (2) is evenly distributed with lifting rollers (21). Several forward synchronous belts (11) are set on one side between the lifting rollers (21), and several reverse synchronous belts (12) are set on the other side. The ends of the forward synchronous belts (11) and the reverse synchronous belts (12) intersect at the center line of the feeding roller table (2). The extruded product group (7) is aligned and gathered at the intersection. If the sensor at the middle position of the extruded product group (7) detects the presence of an empty sensor, it can be considered that the extruded products in the extruded product group (7) are bent or not retracted. The logic of the sensor is as follows: 1) When all sensor signals of the sensor array are continuous, it can be considered that the extruded product group (7) does not have a bending or non-shrinking situation; 2) When the sensor signal of the sensor array is discontinuous, that is, there is a situation where the extruded product is bent or not retracted; Under the premise of the second point, the forward synchronous belt (11) and the reverse synchronous belt (12) move in opposite directions to make the extruded product retract. The sensor signal of the sensor array is checked again to see if it is continuous. If the sensor signal of the sensor array is still discontinuous, it is determined that the extruded product is bent. At this time, manual intervention is required to pick out the bent extruded product.

2. The automatic orientation adjustment method for sawing extruded products according to claim 1, characterized in that: A lateral adjustment belt mechanism (6) is provided at an adjacent position in the direction of travel of the sensor array C (223). The lateral adjustment belt mechanism (6) includes a belt bracket (61). Lifting cylinders (62) are provided on the two columns of the belt bracket (61). The lifting cylinders (62) are installed with a horizontal adjustment timing belt (64) that is perpendicular to the feeding direction of the feed roller table (2). The adjustment timing belt (64) is driven by a belt servo motor (63). The method for calculating the adjustment distance L of the timing belt (64) is: L = (a + c)b / a; where: a is the vertical distance between the center line of sensor array B (222) and the center line of sensor array C (223); c is the distance between the center line of sensor array C (223) and the center line of the transverse adjustment belt mechanism (6); b is the difference between the position of the bottom sensor sensed by sensor array B (222) and the position of the bottom sensor sensed by sensor array C (223).

3. The automatic orientation adjustment method for sawing extruded products according to claim 2, characterized in that: The working logic of the lateral adjustment belt mechanism is as follows: 1) When the sensor signals of the sensor array are all continuous, and the difference between the bottom sensor position sensed by sensor array B (222) and the bottom sensor position sensed by sensor array C (223) is 0, it is considered that the extruded product is perpendicular to the sawing direction. Then the lifting roller lifts up and transports the extruded product to the sawing machine, and the length is fixed by the length-fixing mechanism (5) of the discharge roller table before sawing. 2) When all sensor signals of the sensor array are continuous, and the difference between the bottom sensor position sensed by sensor array B (222) and the bottom sensor position sensed by sensor array C (223) is positive, then the PLC considers that the head of the extruded product group (7) is tilted upward in the figure; the timing belt is adjusted to lift the head of the extruded product group by the cylinder, and the timing belt is adjusted by the servo motor rotating in the forward direction and driven by the gearbox to move a horizontal adjustment distance L, so as to achieve the effect of adjusting the position of the vertical saw blade; 3) When all sensor signals of the sensor array are continuous, and the difference between the lowest sensor position sensed by sensor array B (222) and the lowest sensor position sensed by sensor array C (223) is negative, then the PLC considers that the head of the extruded product group (7) is tilted downward in the figure; the timing belt is adjusted by lifting cylinder (62) to lift the head of the extruded product group (7), and the belt servo motor (63) rotates in the opposite direction to drive the timing belt (64) to move a horizontal adjustment distance L through the gearbox, so as to achieve the effect of adjusting the verticality of the extruded product group (7).

4. The automatic orientation adjustment method for sawing extruded products according to claim 1, characterized in that: The saw (3) is connected to the discharge roller table (4). A length-fixing mechanism (5) is set on one side of the discharge roller table (4). A traveling slide rail (51) and a gear rail (52) are installed on the bracket of the length-fixing mechanism (5). A traveling gear (55) is installed on the length-fixing traveling table (54) and meshes with the gear rail (52). Driven by the traveling motor (53), the traveling table (54) moves on the slide rail (51) using the rail seat. A vertical slide rail (58) is set on the length-fixing traveling table (54). The lifting platform (57) moves up and down along the vertical slide rail (58). The movement involves a fixed-length plate shaft (59) hinged on the lifting platform (57), a worm gear (512) mounted on the fixed-length plate shaft (59), the worm gear (512) meshing with a worm (511) mounted on the lifting platform (57), the worm (511) being driven by a worm motor (510), a fixed-length plate (513) mounted on the fixed-length plate shaft (59), and the fixed-length plate (513) being above the discharge roller table (4); the head of the extruded product group (7) is positioned by abutting the end face of the fixed-length plate (513).

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