Disc shear and method for detecting quality of shearing

Abstract

This invention provides a disc shearing machine and a method for detecting shearing quality. The disc shearing machine includes a frame assembly, a drive assembly, a transmission assembly, an upper cutter head assembly, a lower cutter head assembly, an adjustment assembly, and a detection assembly. The upper and lower cutter head assemblies work together to shear the sheet metal to be processed. The adjustment assembly adjusts the shearing depth of the upper and lower cutter head assemblies on the sheet metal. The detection assembly detects the thickness of the sheet metal, the edge position of the sheet metal, the wear degree of the upper and lower cutter head assemblies, and the shearing depth of the sheet metal, and accordingly controls the operation of the drive assembly, transmission assembly, and adjustment assembly to perform the shearing operation on the sheet metal. This invention achieves real-time monitoring of the shearing process of the sheet metal and detection of shearing quality, effectively reducing subsequent additional quality inspections and / or rework processes, and improving shearing efficiency.

Description

Technical Field

[0001] This invention relates to the field of disc shearing machine technology, and more specifically, to a disc shearing machine and a method for detecting shearing quality. Background Technology

[0002] Shearing is the first step in machining, so disc shears are widely used in actual production. Disc shears use rotating discs as blades, so they can cut strip steel and movable steel plates continuously. Disc shears are usually used on finishing lines to shear the longitudinal edges of movable steel plates into narrow steel strips. Disc shears have advantages such as good rigidity, low energy consumption, stable operation, and convenient operation.

[0003] However, existing disc shearing machines can only perform simple shearing and lack effective quality inspection methods. They struggle to detect and adjust the shearing action on the workpiece during the shearing process, leading to quality problems in the finished workpiece. This necessitates additional quality inspections and / or rework, increasing production costs and time, and reducing processing efficiency. Furthermore, the discs used for shearing (e.g., disc shears) wear down during use, and this wear is not readily observable. Wear also alters the shearing depth, negatively impacting shearing quality. Consequently, the initially set shearing depth may not meet actual quality requirements after disc wear, necessitating manual adjustment based on experience. However, this manual adjustment is highly subjective and cannot accurately guarantee shearing quality. Therefore, existing disc shearing machines cannot meet the demands of efficient and high-quality production. Summary of the Invention

[0004] This invention provides a disc shearing machine and a shearing quality detection method to solve the problem that existing disc shearing machines lack effective quality detection means, making it difficult to detect and adjust the shearing action on the workpiece in a timely manner during processing, resulting in poor workpiece quality after shearing.

[0005] To address the aforementioned problems, according to one aspect of the present invention, a disc shearing machine is provided, comprising: a frame assembly, a drive assembly, a transmission assembly, an upper cutter disc assembly, a lower cutter disc assembly, an adjustment assembly, and a detection assembly; the drive assembly is driven and connected to the upper cutter disc assembly and the lower cutter disc assembly respectively via the transmission assembly, and the drive assembly is used to drive the upper cutter disc assembly and the lower cutter disc assembly to rotate; the transmission assembly is used to adjust the transmission ratio between the drive assembly and the upper cutter disc assembly and the lower cutter disc assembly; the upper cutter disc assembly and the lower cutter disc assembly are rotatably mounted on the frame assembly to jointly perform a shearing operation on the sheet metal to be processed; the adjustment assembly is connected to the upper cutter disc assembly and the lower cutter disc assembly respectively, and is used to adjust the shearing depth of the upper cutter disc assembly and the lower cutter disc assembly on the sheet metal to be processed; wherein, the detection assembly is electrically connected to the drive assembly, the transmission assembly, and the adjustment assembly respectively; the detection assembly controls the operation of the drive assembly, the transmission assembly, and the adjustment assembly accordingly to perform a shearing operation on the sheet metal to be processed by detecting the thickness of the sheet metal to be processed, the edge position of the sheet metal to be processed, the wear degree of the upper cutter disc assembly, the wear degree of the lower cutter disc assembly, and the shearing depth of the sheet metal to be processed.

[0006] Furthermore, the detection components include: a sensor group, an image acquisition unit, and a central controller; the sensor group, image acquisition unit, drive component, transmission component, and adjustment component are electrically connected to the central controller; both the sensor group and the image acquisition unit can be used to detect the thickness of the sheet material to be processed, the edge position of the sheet material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the shearing depth of the sheet material to be processed; wherein, the central controller compares and processes the data collected by the sensor group with the same type of data collected by the image acquisition unit, so as to adjust the operation of the drive component, transmission component, and adjustment component accordingly.

[0007] Furthermore, the image acquisition unit collects and analyzes image information of the sheet material to be processed before and after shearing, and calculates the shearing depth data of the sheet material to be processed, which is the first data; the sensor group detects the sheet material to be processed and obtains the shearing depth data of the sheet material to be processed, which is the second data; the central controller analyzes and processes the first data and the second data to obtain the actual shearing depth of the sheet material to be processed; the central controller compares the actual shearing depth of the sheet material to be processed with the target shearing depth, and adjusts the operation of the drive component, transmission component and adjustment component accordingly.

[0008] Furthermore, when the difference between the actual shearing depth and the target shearing depth of the workpiece exceeds the allowable error range, and the actual shearing depth of the workpiece is less than the target shearing depth, the central controller controls the drive assembly, transmission assembly, and adjustment assembly to operate based on the depth difference, and performs a second shearing on the workpiece according to the depth difference; and / or, when the difference between the actual shearing depth and the target shearing depth of the workpiece exceeds the allowable error range, and the actual shearing depth of the workpiece is greater than the target shearing depth, the central controller determines that the workpiece is a defective workpiece; and / or, when the difference between the actual shearing depth and the target shearing depth of the workpiece exceeds a set value, the central controller, based on the depth difference and combined with the wear data of the upper cutter head assembly and the lower cutter head assembly detected by the sensor group and image acquisition unit, controls the adjustment assembly to adjust the initial distance between the upper cutter head assembly and the lower cutter head assembly to compensate for the shearing depth error caused by the wear of the upper cutter head assembly and the lower cutter head assembly.

[0009] Furthermore, the disc shearing machine also includes a human-machine interface screen, which is electrically connected to the central controller; an image acquisition device captures the working process of the upper and lower cutter head assemblies in real time; the human-machine interface screen displays the real-time data obtained by the central controller and controls the operation and adjusts the parameters of the central controller according to the operator's operation; and / or, the central controller has a data storage function, which records the shearing process of each sheet material to be processed by recording the data collected by the sensor group and the image acquisition device.

[0010] Furthermore, the image acquisition unit collects image information of the upper and lower cutter head assemblies to analyze and obtain wear data of the upper and lower cutter head assemblies, which is the third data. The sensor group detects the upper and lower cutter head assemblies to obtain wear data of the upper and lower cutter head assemblies, which is the fourth data. The central controller analyzes and processes the third and fourth data to obtain the actual wear data of the upper and lower cutter head assemblies. When the actual wear data exceeds the allowable wear range, the central controller controls the drive assembly to stop working and reminds the operator to replace the upper and / or lower cutter head assemblies. And / or, the material information of the material to be processed is input into the central controller, and the central controller adjusts the initial distance between the upper and lower cutter head assemblies and the rotational speed of the upper and lower cutter head assemblies accordingly based on the material information.

[0011] Furthermore, when the difference between the data collected by the sensor group and the same type of data collected by the image acquisition device is within a set error range, the central controller performs a weighted average processing on the same type of data collected by both. The weighted average processing includes: the data collected by the sensor group is X, the same type of data collected by the image acquisition device is Y, and a first weighting coefficient A is obtained based on the manually set and / or the data acquisition accuracy of the sensor group; a second weighting coefficient B is obtained based on the manually set and / or the data acquisition accuracy of the image acquisition device; the central controller calculates D = AX + BY, and then calculates D / (A + B) to obtain the final data of this same type of data; the central controller adjusts the operation of the drive component, transmission component, and adjustment component accordingly based on the final data; and / or, when the difference between the data collected by the sensor group and the same type of data collected by the image acquisition device exceeds the set error range, the central controller issues an alarm message to remind the staff to make a manual judgment and / or manually control the operation of the drive component, transmission component, and adjustment component.

[0012] Furthermore, the sensor group includes an ultrasonic thickness sensor, a laser edge position sensor, and an eddy current tool wear sensor; the ultrasonic thickness sensor is used to detect the thickness of the material to be processed and / or the shearing depth of the material to be processed; the laser edge position sensor is used to detect the edge position of the material to be processed; the eddy current tool wear sensor is used to detect the wear degree of the upper cutter head assembly and the wear degree of the lower cutter head assembly; and / or, the central controller uses a fuzzy logic algorithm to compare and process the data collected by the sensor group with the same data collected by the image acquisition unit, and calculates the corresponding adjustment parameters to adjust the operation of the drive assembly, transmission assembly, and adjustment assembly accordingly.

[0013] Furthermore, the detection component also includes a material detector, which obtains material information by detecting the material of the sheet to be processed. The detection component adjusts the initial distance between the upper and lower cutter head assemblies and the rotational speed of the upper and lower cutter head assemblies accordingly based on the material information; and / or, the disc shearing machine also includes a feeding assembly, which is used to transport the sheet to be processed to the designated shearing position; and / or, the disc shearing machine also includes a housing assembly, which is mounted on the frame assembly and covers the upper and lower cutter head assemblies to isolate them from the outside environment.

[0014] According to another aspect of the present invention, a shearing quality detection method is provided for use in the aforementioned disc shearing machine. The shearing quality detection method includes the following steps: detecting the thickness of the sheet material to be processed, the edge position of the sheet material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the actual shearing depth of the sheet material to be processed; comparing the actual shearing depth of the sheet material to be processed with a target shearing depth; when the depth difference between the actual shearing depth and the target shearing depth exceeds the allowable error range, and the actual shearing depth of the sheet material to be processed is less than the target shearing depth, based on the depth difference... The material to be processed is subjected to secondary shearing based on the depth difference. When the depth difference between the actual shearing depth and the target shearing depth of the material to be processed exceeds the allowable error range, and the actual shearing depth of the material to be processed is greater than the target shearing depth, the material to be processed is identified as unqualified. When the depth difference between the actual shearing depth and the target shearing depth of the material to be processed exceeds the set value, the initial distance between the upper and lower cutter heads is adjusted accordingly based on the depth difference and the wear degree of the upper and lower cutter heads to compensate for the shearing depth error caused by the wear of the upper and lower cutter heads.

[0015] According to the technical solution of this invention, a disc shearing machine is provided, comprising: a frame assembly, a drive assembly, a transmission assembly, an upper cutter disc assembly, a lower cutter disc assembly, an adjustment assembly, and a detection assembly; the drive assembly is driven and connected to the upper cutter disc assembly and the lower cutter disc assembly respectively through the transmission assembly, and the drive assembly is used to drive the upper cutter disc assembly and the lower cutter disc assembly to rotate; the transmission assembly is used to adjust the transmission ratio between the drive assembly and the upper cutter disc assembly and the lower cutter disc assembly; the upper cutter disc assembly and the lower cutter disc assembly are rotatably mounted on the frame assembly to jointly perform a shearing operation on the material to be processed; the adjustment assembly is connected to the upper cutter disc assembly and the lower cutter disc assembly respectively, and is used to adjust the shearing depth of the upper cutter disc assembly and the lower cutter disc assembly on the material to be processed; wherein, the detection assembly is electrically connected to the drive assembly, the transmission assembly, and the adjustment assembly respectively; the detection assembly controls the operation of the drive assembly, the transmission assembly, and the adjustment assembly accordingly to perform a shearing operation on the material to be processed by detecting the thickness of the material to be processed, the edge position of the material to be processed, the wear degree of the upper cutter disc assembly, the wear degree of the lower cutter disc assembly, and the shearing depth of the material to be processed.

[0016] This invention, through the coordinated operation of a frame assembly, drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, adjustment assembly, and detection assembly, enables real-time monitoring and quality detection of the shearing process of the sheet metal on a disc shearing machine. It allows for the timely detection of quality issues during shearing and the adaptive adjustment of the drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, and adjustment assembly to mitigate these issues. This effectively reduces subsequent additional quality inspections and / or rework, lowering production costs and timelines while improving processing efficiency. Simultaneously, the detection assembly monitors the wear levels of both the upper and lower cutter head assemblies, enabling real-time monitoring of their wear conditions. The adjustment assembly adjusts the initial distance between the upper and lower cutter head assemblies. This invention compensates for the shearing depth error caused by wear of the upper and lower cutter head assemblies. This ensures that the subsequent shearing quality effectively meets actual shearing quality requirements even after the discs wear down, eliminating the need for manual adjustment of the shearing depth and avoiding the adverse effects of subjective human intervention. This guarantees the shearing quality of the processed material. Furthermore, by integrating detection components, this invention achieves real-time monitoring and automatic adjustment of the material shearing process, ensuring the stability and consistency of shearing quality. This further improves production efficiency and product quality, reduces manual intervention, and lowers production costs. Overall, this invention has a simple and low-cost structure, is easy to assemble and maintain, and significantly improves the intelligence and automation level of the disc shearing machine, bringing significant benefits to the field of material shearing and making it suitable for large-scale promotion and use. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0018] Figure 1 A schematic flowchart of some steps of the shear quality detection method provided by an embodiment of the present invention is shown. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] An embodiment of the present invention provides a disc shearing machine, comprising: a frame assembly, a drive assembly, a transmission assembly, an upper cutter disc assembly, a lower cutter disc assembly, an adjustment assembly, and a detection assembly; the drive assembly is driven to rotate the upper and lower cutter disc assemblies via the transmission assembly; the transmission assembly is used to adjust the transmission ratio between the drive assembly and the upper and lower cutter disc assemblies; the upper and lower cutter disc assemblies are rotatably mounted on the frame assembly to jointly perform shearing operations on the sheet metal to be processed; the adjustment assembly is connected to the upper and lower cutter disc assemblies to adjust the shearing depth of the upper and lower cutter disc assemblies on the sheet metal to be processed; wherein, the detection assembly is electrically connected to the drive assembly, the transmission assembly, and the adjustment assembly; the detection assembly controls the operation of the drive assembly, the transmission assembly, and the adjustment assembly accordingly to perform shearing operations on the sheet metal to be processed by detecting the thickness of the sheet metal to be processed, the edge position of the sheet metal to be processed, the wear degree of the upper cutter disc assembly, the wear degree of the lower cutter disc assembly, and the shearing depth of the sheet metal to be processed.

[0021] This invention, through the coordinated operation of a frame assembly, drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, adjustment assembly, and detection assembly, enables real-time monitoring and quality detection of the shearing process of the sheet metal on a disc shearing machine. It allows for the timely detection of quality issues during shearing and the adaptive adjustment of the drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, and adjustment assembly to mitigate these issues. This effectively reduces subsequent additional quality inspections and / or rework, lowering production costs and timelines while improving processing efficiency. Simultaneously, the detection assembly monitors the wear levels of both the upper and lower cutter head assemblies, enabling real-time monitoring of their wear conditions. The adjustment assembly adjusts the initial distance between the upper and lower cutter head assemblies. This invention compensates for the shearing depth error caused by wear of the upper and lower cutter head assemblies. This ensures that the subsequent shearing quality effectively meets actual shearing quality requirements even after the discs wear down, eliminating the need for manual adjustment of the shearing depth and avoiding the adverse effects of subjective human intervention. This guarantees the shearing quality of the processed material. Furthermore, by integrating detection components, this invention achieves real-time monitoring and automatic adjustment of the material shearing process, ensuring the stability and consistency of shearing quality. This further improves production efficiency and product quality, reduces manual intervention, and lowers production costs. Overall, this invention has a simple and low-cost structure, is easy to assemble and maintain, and significantly improves the intelligence and automation level of the disc shearing machine, bringing significant benefits to the field of material shearing and making it suitable for large-scale promotion and use.

[0022] Specifically, the detection components include: a sensor group, an image acquisition unit, and a central controller; the sensor group, image acquisition unit, drive component, transmission component, and adjustment component are electrically connected to the central controller; both the sensor group and the image acquisition unit can be used to detect the thickness of the material to be processed, the edge position of the material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the shearing depth of the material to be processed; wherein, the central controller compares and processes the data collected by the sensor group with the same data collected by the image acquisition unit, so as to adjust the operation of the drive component, transmission component, and adjustment component accordingly.

[0023] By setting the specific structure of the detection components, the disc shearing machine can acquire real-time data of the workpiece and the upper and lower cutter heads through two different detection methods. This analysis and comparison of multi-source data improves the reliability of the data, ensures the accuracy of the shearing depth adjustment, thereby improving the quality consistency of the sheared products and reducing the errors that may be caused by a single detection method.

[0024] Specifically, the image acquisition unit collects and analyzes image information of the sheet material to be processed before and after shearing, and calculates the shearing depth data of the sheet material to be processed, which is the first data; the sensor group detects the sheet material to be processed and obtains the shearing depth data of the sheet material to be processed, which is the second data; the central controller analyzes and processes the first data and the second data to obtain the actual shearing depth of the sheet material to be processed; the central controller compares the actual shearing depth of the sheet material to be processed with the target shearing depth, and adjusts the operation of the drive component, transmission component and adjustment component accordingly.

[0025] By comprehensively analyzing image information and sensor data, the central controller can more accurately calculate the actual shearing depth of the material to be processed. This allows for secondary shearing or marking of defective materials when a shearing depth deviation is detected, through adjustments to the drive, transmission, and adjustment components. This effectively controls shearing precision, avoids waste in subsequent processes, and improves overall production efficiency.

[0026] Optionally, when the difference between the actual shearing depth and the target shearing depth of the workpiece exceeds the allowable error range, and the actual shearing depth of the workpiece is less than the target shearing depth, the central controller controls the drive assembly, transmission assembly, and adjustment assembly to operate according to the depth difference, and performs a second shearing on the workpiece according to the depth difference; and / or, when the difference between the actual shearing depth and the target shearing depth of the workpiece exceeds the allowable error range, and the actual shearing depth of the workpiece is greater than the target shearing depth, the central controller determines that the workpiece is a defective workpiece; and / or, when the difference between the actual shearing depth and the target shearing depth of the workpiece exceeds a set value, the central controller controls the adjustment assembly to adjust the initial distance between the upper and lower cutter heads according to the depth difference, combined with the wear data of the upper cutter head assembly and the lower cutter head assembly detected by the sensor group and the image acquisition unit, to compensate for the shearing depth error caused by the wear of the upper and lower cutter head assemblies.

[0027] With the above settings, when dealing with the deviation between the shearing depth and the target shearing depth of the sheet metal, the central controller can adopt different strategies, such as secondary shearing or directly marking it as unqualified to stop further processing. At the same time, the central controller can also automatically adjust the initial distance between the cutter heads based on the tool wear data to compensate for the shearing depth error caused by wear. This not only improves product quality but also extends the service life of the upper and lower cutter head assemblies and reduces maintenance costs.

[0028] Specifically, the disc shearing machine also includes a human-machine interface screen, which is electrically connected to the central controller; an image acquisition device captures the working process of the upper and lower cutter head assemblies in real time; the human-machine interface screen displays the real-time data obtained by the central controller and controls the operation and adjusts the parameters of the central controller according to the operator's operation; and / or, the central controller has a data storage function, which records the shearing process of each sheet material to be processed by recording the data collected by the sensor group and the image acquisition device.

[0029] The human-machine interface allows staff to monitor the shearing process and data in real time and make necessary parameter adjustments. The image acquisition device visualizes the shearing process, improves the transparency of the shearing work, and makes it easier for staff to identify and resolve potential problems in a timely manner, such as abnormal blades or abnormal plate feeding. This enhances the working stability and safety of the disc shearing machine and reduces downtime caused by accidents.

[0030] Optionally, the image acquisition unit acquires image information of the upper cutter head assembly and the lower cutter head assembly to analyze and obtain wear degree data of the upper cutter head assembly and the lower cutter head assembly, which is the third data; the sensor group detects the upper cutter head assembly and the lower cutter head assembly to obtain wear degree data of the upper cutter head assembly and the lower cutter head assembly, which is the fourth data; the central controller analyzes and processes the third data and the fourth data to obtain the actual wear data of the upper cutter head assembly and the lower cutter head assembly. When the actual wear data exceeds the allowable wear range, the central controller controls the drive assembly to stop working and reminds the operator to replace the upper cutter head assembly and / or the lower cutter head assembly; and / or, the material information of the material to be processed is input into the central controller, and the central controller adjusts the initial distance between the upper cutter head assembly and the lower cutter head assembly, as well as the rotation speed of the upper cutter head assembly and the lower cutter head assembly, according to the material information.

[0031] Through dual monitoring of image information and sensor data, the central controller can more accurately assess tool wear and automatically remind users to replace tools, avoiding a decrease in shearing quality due to excessive tool wear. At the same time, this setting allows the central controller to adjust the initial distance and speed between the cutter heads according to the material of the sheet metal. This enables the machine to adapt to different sheet metal materials, improving its working flexibility and processing range, and ensuring the shearing quality of different sheet metal materials.

[0032] Optionally, when the difference between the data collected by the sensor group and the same type of data collected by the image acquisition device is within a set error range, the central controller performs a weighted average processing on the same type of data collected by both. The weighted average processing includes: the data collected by the sensor group is X, the same type of data collected by the image acquisition device is Y, and a first weighting coefficient A is obtained according to the manual setting and / or the data acquisition accuracy of the sensor group; a second weighting coefficient B is obtained according to the manual setting and / or the data acquisition accuracy of the image acquisition device; the central controller calculates D = AX + BY, and then calculates D / (A + B) to obtain the final data of this same type of data; the central controller adjusts the operation of the drive component, transmission component, and adjustment component accordingly based on the final data; and / or, when the difference between the data collected by the sensor group and the same type of data collected by the image acquisition device exceeds the set error range, the central controller issues an alarm message to remind the staff to make a manual judgment and / or manually control the operation of the drive component, transmission component, and adjustment component.

[0033] The weighted average processing of data from the sensor group and image acquisition unit improves the accuracy and reliability of the data. When the data difference exceeds the set error range, the system issues an alarm message, prompting the staff to intervene manually, thus ensuring the safe operation of the disc shear machine under special circumstances and avoiding production accidents caused by data errors.

[0034] Optionally, the sensor group includes an ultrasonic thickness sensor, a laser edge position sensor, and an eddy current tool wear sensor; the ultrasonic thickness sensor is used to detect the thickness of the material to be processed and / or the shearing depth of the material to be processed; the laser edge position sensor is used to detect the edge position of the material to be processed; the eddy current tool wear sensor is used to detect the wear degree of the upper cutter head assembly and the wear degree of the lower cutter head assembly; and / or, the central controller uses a fuzzy logic algorithm to compare and process the data collected by the sensor group with the same data collected by the image acquisition unit, and calculates the corresponding adjustment parameters to adjust the operation of the drive assembly, transmission assembly, and adjustment assembly accordingly.

[0035] By setting detailed configurations for the sensor array and employing fuzzy logic algorithms in the central controller, the level of intelligence in data processing has been improved, enabling more accurate comparison and processing of data and calculation of adjustment parameters. The application of fuzzy logic algorithms allows the central controller to adaptively adjust parameters according to different detection needs and environmental changes, further enhancing shearing accuracy and efficiency.

[0036] Specifically, the detection component also includes a material detector, which obtains material information by detecting the material of the sheet to be processed. The detection component adjusts the initial distance between the upper and lower cutter head assemblies and the rotational speed of the upper and lower cutter head assemblies accordingly based on the material information; and / or, the disc shearing machine also includes a feeding assembly, which is used to transport the sheet to be processed to the designated shearing position; and / or, the disc shearing machine also includes a housing assembly, which is mounted on the frame assembly and covers the upper and lower cutter head assemblies to isolate them from the outside environment.

[0037] The addition of a material detector enables the central controller to automatically adjust the cutter head parameters according to the material of the sheet metal. This not only improves the shearing quality and efficiency but also enhances the machine's adaptability to handling different sheet metal materials. The design of the feeding assembly and the housing assembly optimizes the sheet metal conveying process and the machine's enclosure, improving production safety and reducing external environmental interference with the shearing process.

[0038] like Figure 1As shown, the present invention also provides a shearing quality detection method for the aforementioned disc shearing machine. The shearing quality detection method includes the following steps: detecting the thickness of the sheet material to be processed, the edge position of the sheet material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the actual shearing depth of the sheet material to be processed; comparing the actual shearing depth of the sheet material to be processed with the target shearing depth; when the depth difference between the actual shearing depth and the target shearing depth exceeds the allowable error range, and the actual shearing depth of the sheet material to be processed is less than the target shearing depth, based on the depth difference, the shearing quality detection method is determined. The processing sheet is subjected to secondary shearing based on the depth difference. When the depth difference between the actual shearing depth and the target shearing depth of the sheet to be processed exceeds the allowable error range, and the actual shearing depth of the sheet to be processed is greater than the target shearing depth, the sheet to be processed is identified as unqualified. When the depth difference between the actual shearing depth and the target shearing depth of the sheet to be processed exceeds the set value, the initial distance between the upper and lower cutter heads is adjusted accordingly based on the depth difference and the wear degree of the upper and lower cutter heads to compensate for the shearing depth error caused by the wear of the upper and lower cutter heads.

[0039] The shearing quality detection method proposed in this invention is a comprehensive application based on the above-mentioned structure and control strategy, aiming to achieve precise control of the shearing depth of the sheet metal. Through real-time detection and adaptive adjustment, this method can effectively deal with various problems that may be encountered during the shearing process of sheet metal (such as inconsistent shearing depth, uneven sheet metal edges, or tool wear), ensuring shearing quality, reducing the need for subsequent quality inspection steps, and thus significantly improving production efficiency and economic benefits.

[0040] In a specific embodiment of the present invention, the shearing quality detection method proposed in the present invention further includes the following steps: S1, acquiring cross-sectional images of the plate after disc shearing in real time; S2, using an image acquisition device and a central controller, extracting two boundary lines and the dividing line between the cut layer and the tear layer in the cross-sectional image using grayscale morphology algorithm and edge detection algorithm, thereby obtaining the width of the cut layer corresponding to the cross-sectional image, and using the width of the cut layer as the real-time shearing depth; S3, comparing the obtained real-time shearing depth with the target shearing depth, and if the difference between the two is greater than a preset maximum threshold, sending the obtained real-time shearing depth to the operator so that the operator can manually adjust various parameters according to the real-time shearing depth.

[0041] The specific working process and principle of one embodiment of the present invention will now be described in detail as follows:

[0042] The disc shearing machine includes a frame assembly, left and right disc housing assemblies, a transmission assembly, and an adjustment assembly for adjusting the cutter shaft, cutter disc, and opening degree. A rotatable upper cutter disc assembly and a lower cutter disc assembly are mounted on the frame assembly to jointly perform shearing operations on the sheet metal. A feeding assembly is installed at the front end of the frame assembly and can stably transport the sheet metal between the upper and lower cutter disc assemblies for shearing.

[0043] Before starting the disc shear, input parameters such as the material, thickness, target shearing depth, and width of the sheet material to be processed. The central controller initializes the equipment's operating parameters based on these input parameters, including the initial distance between the upper and lower cutter head assemblies and the motor speed in the drive assembly. After starting the disc shear, the sheet material begins to enter the shear. The sensor group and image acquisition unit in the detection assembly start working, collecting data in real time on the sheet material's thickness, edge position, wear degree of the upper and lower cutter head assemblies, and shearing depth, and transmitting this data to the data processing and analysis unit of the central controller.

[0044] When a cutting depth deviation is detected in the sheared sheet, the central controller calculates the corresponding control adjustment parameters based on the pre-input intelligent algorithm, and then adjusts the drive component, transmission component and adjustment component accordingly to adjust the processing parameters of the disc shear for the sheet.

[0045] Throughout the shearing process, the human-machine interface displays various data, the operating status of each component, and the adjustment process and results of the central controller in real time, allowing staff to view them at any time. If equipment failure or quality problems occur, the human-machine interface will promptly issue an alarm signal, and staff can take appropriate action based on the alarm information (such as stopping the machine for inspection, replacing the cutting tool, etc.). After shearing is completed, the central controller automatically records all parameters and data during the processing, forming a processing log. This data can be used for subsequent quality analysis, equipment maintenance, and process optimization.

[0046] This invention enables real-time monitoring and automatic adjustment of the sheet metal shearing process, ensuring the stability and consistency of shearing quality. The automatic recording function of the image acquisition device and the remote operation command receiving capability of the central controller enhance the intelligence level of the disc shearing machine, facilitating data analysis and remote equipment management. The tool can be subsequently integrated with an automatic tool changing system, and combined with existing edge quality assessment algorithms, further improving production efficiency and product quality, reducing manual intervention, and lowering production costs.

[0047] In summary, this invention provides a disc shearing machine and a shearing quality detection method. By setting up a frame assembly, drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, adjustment assembly, and detection assembly to work together, this invention achieves real-time monitoring and shearing quality detection of the shearing process of the sheet metal on the disc shearing machine. It can promptly detect quality problems during shearing and improve these problems by adaptively adjusting the drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, and adjustment assembly. This effectively reduces subsequent additional quality inspections and / or rework processes, lowering shearing production costs and cycle time, and improving shearing efficiency. Simultaneously, the detection assembly monitors the wear degree of the upper and lower cutter head assemblies, enabling real-time detection of their wear conditions. The adjustment assembly further optimizes the wear of the upper cutter head assembly. Adjusting the initial distance between the upper and lower cutter head assemblies compensates for the shearing depth error caused by wear on both assemblies. This ensures that even after disc wear, the subsequent shearing quality effectively meets actual shearing requirements, eliminating the need for manual adjustment of the shearing depth and avoiding the adverse effects of subjective human intervention. This guarantees the shearing quality of the processed material. Furthermore, by integrating detection components, this invention achieves real-time monitoring and automatic adjustment of the shearing process, ensuring the stability and consistency of shearing quality. This further improves production efficiency and product quality, reduces manual intervention, and lowers production costs. Overall, this invention has a simple and low-cost structure, is easy to assemble and maintain, and significantly enhances the intelligence and automation level of the disc shearing machine, bringing significant benefits to the field of sheet metal shearing and making it suitable for large-scale promotion and use.

[0048] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0049] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0050] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms 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 the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0051] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0052] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0053] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A disc shearing machine, characterized in that, include: Frame assembly, drive assembly, transmission assembly, upper cutter head assembly, lower cutter head assembly, adjustment assembly, and detection assembly; The drive assembly is connected to the upper cutter head assembly and the lower cutter head assembly via the transmission assembly, and the drive assembly drives the upper cutter head assembly and the lower cutter head assembly to rotate. The transmission assembly adjusts the transmission ratio between the drive assembly and the upper cutter head assembly and the lower cutter head assembly. The upper cutter head assembly and the lower cutter head assembly are rotatably mounted on the frame assembly to jointly perform a shearing operation on the material to be processed. The adjustment assembly is connected to the upper cutter head assembly and the lower cutter head assembly, and is used to adjust the shearing depth of the upper cutter head assembly and the lower cutter head assembly on the material to be processed. The detection assembly is electrically connected to the drive assembly, the transmission assembly, and the adjustment assembly. The detection assembly detects the thickness of the material to be processed, the edge position of the material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the shearing depth of the material to be processed, and accordingly controls the operation of the drive assembly, the transmission assembly, and the adjustment assembly to perform a shearing operation on the material to be processed. The detection component includes a sensor group, an image acquisition unit, and a central controller. The sensor group, the image acquisition unit, the drive component, the transmission component, and the adjustment component are electrically connected to the central controller. Both the sensor group and the image acquisition unit can be used to detect the thickness of the sheet material to be processed, the edge position of the sheet material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the shearing depth of the sheet material to be processed. The central controller compares and processes the data collected by the sensor group with the same data collected by the image acquisition unit to adjust the operation of the drive component, the transmission component, and the adjustment component accordingly. When the difference between the data collected by the sensor group and the same type of data collected by the image acquisition device is within a set error range, the central controller performs a weighted average processing on the same type of data collected by both. The weighted average processing includes: the data collected by the sensor group is X, the same type of data collected by the image acquisition device is Y, and a first weighting coefficient A is obtained according to a manual setting and / or the data acquisition accuracy of the sensor group; a second weighting coefficient B is obtained according to a manual setting and / or the data acquisition accuracy of the image acquisition device; the central controller calculates D=AX+BY, and then calculates D / (A+B) to obtain the final data of this same type of data; the central controller adjusts the operation of the drive component, the transmission component, and the adjustment component accordingly based on the final data. The sensor group includes an ultrasonic thickness sensor, a laser edge position sensor, and an eddy current tool wear sensor; the ultrasonic thickness sensor is used to detect the thickness of the workpiece and / or the shearing depth of the workpiece; the laser edge position sensor is used to detect the edge position of the workpiece; and the eddy current tool wear sensor is used to detect the wear degree of the upper cutter head assembly and the wear degree of the lower cutter head assembly.

2. The disc shearing machine according to claim 1, characterized in that, The image acquisition device collects and analyzes image information of the sheet material to be processed before and after shearing, and calculates the shearing depth data of the sheet material to be processed, which is the first data; the sensor group detects the sheet material to be processed and obtains the shearing depth data of the sheet material to be processed, which is the second data; the central controller analyzes and processes the first data and the second data to obtain the actual shearing depth of the sheet material to be processed; the central controller compares the actual shearing depth of the sheet material to be processed with the target shearing depth to adjust the operation of the drive component, the transmission component and the adjustment component accordingly.

3. The disc shearing machine according to claim 2, characterized in that, When the difference between the actual shearing depth of the material to be processed and the target shearing depth exceeds the allowable error range, and the actual shearing depth of the material to be processed is less than the target shearing depth, the central controller controls the drive component, the transmission component and the adjustment component to work according to the depth difference, and performs a second shearing on the material to be processed according to the depth difference; And / or, when the difference between the actual shearing depth and the target shearing depth of the material to be processed exceeds the allowable error range, and the actual shearing depth of the material to be processed is greater than the target shearing depth, the central controller determines that the material to be processed is a defective material; And / or, when the difference between the actual shearing depth of the workpiece and the target shearing depth exceeds a set value, the central controller, based on the depth difference and in conjunction with the wear data of the upper cutter head assembly and the lower cutter head assembly detected by the sensor group and the image acquisition device, controls the adjustment component to adjust the initial distance between the upper cutter head assembly and the lower cutter head assembly to compensate for the shearing depth error caused by the wear of the upper cutter head assembly and the lower cutter head assembly.

4. The disc shearing machine according to claim 1, characterized in that, The disc shearing machine also includes a human-machine interface screen, which is electrically connected to the central controller; the image acquisition device captures the working process of the upper cutter head assembly and the lower cutter head assembly in real time; the human-machine interface screen displays the real-time data obtained by the central controller and controls the operation and adjusts the parameters of the central controller according to the operator's operation; And / or, the central controller has a data storage function, which records the shearing process of each of the plates to be processed by recording the data collected by the sensor group and the image acquisition device.

5. The disc shearing machine according to claim 1, characterized in that, The image acquisition device acquires image information of the upper cutter head assembly and the lower cutter head assembly to analyze and obtain wear degree data of the upper cutter head assembly and the lower cutter head assembly, which is the third data; the sensor group detects the upper cutter head assembly and the lower cutter head assembly to obtain wear degree data of the upper cutter head assembly and the lower cutter head assembly, which is the fourth data; the central controller analyzes and processes the third data and the fourth data to obtain the actual wear data of the upper cutter head assembly and the lower cutter head assembly. When the actual wear data exceeds the allowable wear range, the central controller controls the drive assembly to stop working and reminds the operator to replace the upper cutter head assembly and / or the lower cutter head assembly. And / or, input the material information of the material to be processed to the central controller, and the central controller adjusts the initial distance between the upper cutter head assembly and the lower cutter head assembly, and the rotational speed of the upper cutter head assembly and the lower cutter head assembly accordingly based on the material information.

6. The disc shearing machine according to claim 1, characterized in that, When the difference between the data collected by the sensor group and the same data collected by the image acquisition device exceeds the set error range, the central controller issues an alarm message to remind the staff to make a manual judgment and / or manually control the operation of the drive component, the transmission component and the adjustment component.

7. The disc shearing machine according to claim 1, characterized in that, The central controller uses a fuzzy logic algorithm to compare and process the data collected by the sensor group with the same data collected by the image acquisition device, and calculates the corresponding adjustment parameters to adjust the operation of the drive component, the transmission component and the adjustment component accordingly.

8. The disc shearing machine according to claim 1, characterized in that, The detection component also includes a material detector, which obtains material information by detecting the material of the material to be processed. The detection component adjusts the initial distance between the upper cutter head assembly and the lower cutter head assembly, as well as the rotational speed of the upper cutter head assembly and the lower cutter head assembly, according to the material information. And / or, the disc shearing machine further includes a feeding assembly for transporting the sheet material to be processed to a designated shearing position; And / or, the disc shearing machine further includes a housing assembly disposed on the frame assembly and covering the exterior of the upper cutter head assembly and the lower cutter head assembly, for separating the upper cutter head assembly and the lower cutter head assembly from the outside environment.

9. A method for detecting shear quality, characterized in that, The shearing quality detection method is used in the disc shearing machine according to any one of claims 1 to 8, and the shearing quality detection method includes the following steps: The thickness of the material to be processed, the edge position of the material to be processed, the wear degree of the upper cutter head assembly, the wear degree of the lower cutter head assembly, and the actual shearing depth of the material to be processed are detected. Compare the actual shearing depth of the material to be processed with the target shearing depth; When the difference between the actual shearing depth and the target shearing depth of the material to be processed exceeds the allowable error range, and the actual shearing depth of the material to be processed is less than the target shearing depth, the material to be processed is sheared a second time according to the depth difference. When the difference between the actual shearing depth and the target shearing depth of the material to be processed exceeds the allowable error range, and the actual shearing depth of the material to be processed is greater than the target shearing depth, the material to be processed is deemed to be a defective material. When the difference between the actual shearing depth of the material to be processed and the target shearing depth exceeds a set value, the initial distance between the upper cutter head assembly and the lower cutter head assembly is adjusted according to the depth difference and the wear degree of the upper cutter head assembly and the lower cutter head assembly to compensate for the shearing depth error caused by the wear of the upper cutter head assembly and the lower cutter head assembly.

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