Full-automatic band saw blade cutting system

Abstract

The invention discloses a full-automatic band saw blade tailoring system, and relates to the technical field of band saw blade tailoring, the full-automatic band saw blade tailoring system specifically comprises a detection unit, a conveying unit, a tailoring unit and a control unit, the detection unit comprises a group of laser sensors, and the laser sensors are used for collecting tooth profile data of a band saw blade tailored for the first time; the collected data is sent to the control unit; the group of laser sensors comprise a laser sensor S1 and a laser sensor S2, and the laser sensor S2 is located above the laser sensor S1; the conveying unit comprises two feeding wheel sets, each feeding wheel set comprises two feeding wheels, and the conveying unit is located below the detection unit; the cutting unit comprises a movable cutter and a fixed cutter. A complete feeding, tooth searching and cutting system is formed through a set of laser sensors, a high-precision feeding wheel and a self-adaptive algorithm, the problem that automatic length fixing is difficult and inaccurate in a manual tooth searching and meter counting mode is solved through the system, and the cutting efficiency and the cutting precision of the band saw blade are improved.

Description

Technical Field

[0001] The invention relates to the technical field of band saw blade cutting, in particular to a full-automatic band saw blade cutting system. Background Art

[0002] Band saw is a machine that uses a ring-shaped endless band saw blade to continuously rotate in the same direction around two saw wheels to perform sawing. Band saw machines have high efficiency and small saw paths. They are the most widely used main saw machines in my country's wood processing equipment. Band saw blades are an important component of band saws. During the processing of band saw blades, they need to be cut to a certain length, and then the two sides of the saw blade are welded together, and the welds are annealed and sandblasted to finally form a circle of saw blades.

[0003] In the prior art, the cutting of saw blades mainly relies on manual judgment of the cutting position. The manual cutting accuracy is poor and the position selection is inaccurate under different tooth shapes. The same type of equipment can only achieve cutting with fixed tooth shapes, and cannot adjust and select the cutting point position adaptively according to different tooth shapes. Summary of the invention

[0004] The present invention provides a fully automatic band saw blade cutting system, which solves the problems of low cutting accuracy, low cutting efficiency and poor adaptability of band saw blades proposed in the above background technology.

[0005] The present invention provides the following technical solution: a fully automatic band saw blade cutting system, comprising a detection unit, a conveying unit, a cutting unit and a control unit, wherein the detection unit comprises a group of laser sensors, the laser sensors are used to collect tooth shape data of the band saw blade cut for the first time, and send the collected data to the control unit; the group of laser sensors is divided into a laser sensor S1 and a laser sensor S2, and the laser sensor S2 is located above the laser sensor S1;

[0006] The conveying unit includes two feeding wheel groups, each feeding wheel group includes two feeding wheels, and the conveying unit is located below the detection unit;

[0007] The cutting unit includes a movable cutter and a fixed cutter; the movable cutter is driven by a driving structure and is located above the fixed cutter; the fixed cutter is fixed in position, the fixed cutter and the movable cutter are in a staggered state, and the side of the fixed cutter away from the conveying unit and the side of the movable cutter close to the conveying unit are in the same plane; the laser sensor S2 is located on the side of the laser sensor S1 close to the fixed cutter, and the distance D1 between the side of the movable cutter close to the conveying unit and the laser sensor S1 is fixed;

[0008] The control unit is respectively connected to the detection unit, the conveying unit and the cutting unit. The control unit calculates the optimal cutting point and length by using an adaptive algorithm, makes the length of the saw blade close to an integer multiple of the number of tooth groups, and automatically prompts whether the current material is sufficient to complete the order cutting according to the length data converted by weight with the support of the basic parameters. At the same time, it detects the tips of the saw blade teeth and timely feedbacks material problems such as the bending of the saw blade, tooth loss, and tooth damage;

[0009] The adaptive algorithm is implemented according to the following steps:

[0010] Step 1: Tooth profile learning (entry)

[0011] Enter the tooth groove position S1 and tooth pitch T recorded by the laser sensor i ;

[0012] Step 2: First cut positioning (first tooth search)

[0013] a. The laser sensor identifies STS tooth pitches T of the minimum search tooth pitch, and confirms the tooth tip point P at the current laser sensor S1 by comparing the tooth pitches i , and; i ;

[0014] b. Search backward from the position of P i to find the position of the first cut S k , and calculate the distance between P i and the set first cut S k , which is set as FCL; k+1 ;

[0015] c. The nearest first cut distance D2 = D1 - [(FCL + D1) / TSL]*TSL, where TSL is the tooth group length, D1 is the saw blade length, and D1 >> TSL;

[0016] If D2 ≥ KL, the feed length for tooth search and cutting - 1: FCL_1 = D2 - KL, where KL is the reserved length, which refers to the length reserved forward or backward from the P i point during the cutting process;

[0017] If D2 < KL, the feed length for tooth search and cutting - 1: FCL_1 = D2 + TSL - KL;

[0018] Feed the length of FCL_1, cut with the knife, and obtain the first cut at the position of S k , and reserve the cut to the front end of the KL length at the position of P k+1 ;

[0019] Step 3: Output the intermediate length

[0020] d. The number of feed tooth groups K, K = [(OL-ATL) / TSL], where: OL is the required length of the order, ATL is the average tooth spacing, the average value of the tooth spacing within a set of tooth groups;

[0021] e. Feed length FL after first cutting 首 The calculation formula is: FL 首 =(K-1)*TSL+KL;

[0022] f. After the feed wheel is fed by FL, it will move to the nearest P i Click to stop and record the current FL i ;

[0023] Step 4: Tail knife positioning (second tooth search)

[0024] G. Laser sensor identifies the number of feed tooth groups SKS and the tooth spacing T i , by comparing the tooth spacing T i Confirm the current P at S1 i , record the SKS tooth spacing T of the identification process feed i At this time, the tail knife feed length FL 尾 =FL i +Σ(T i ), assign the current total feed amount to FCL_2, FCL_2 = FL 尾 ;

[0025] D3 is the tail knife P i The distance from the point to the CP point; D3 = D1-[D1 / TSL]*TSL, D3 is greater than TSL and greater than 0; where: the CP point is the point where the cutter is close to the conveying unit;

[0026] Final feed length FL 终 =FL 尾 +D3+KL;

[0027] Enter the loop judgment:

[0028] FL 终 ≥CL-TN, TN is the negative tolerance;

[0029] ——Yes, end the loop and output FL 终 , output refeed amount LFL = FL 终 -FCL_2;

[0030] ——No, FL 终 =FL 尾 +T i ;

[0031] Enter the nested loop judgment:

[0032] FL 终 ≤CL+TP, TP is the positive tolerance

[0033] ——Yes, continue the cycle;

[0034] ——No, report an error, exceed the error adjustment formula or error upper limit.

[0035] Preferably, the laser sensor is equipped with a high-precision encoder, and the data collected by the laser sensor include band saw width b, band saw thickness s, tooth groove depth h, tooth pitch t, ​​front angle α, back angle γ and total tooth quantity w.

[0036] Preferably, the driving structure is a hydraulic driving structure; and D1 is 185 mm.

[0037] Preferably, the laser sensor is moved to a position of about 40% of the vertical depth of the tooth groove, and the tooth spacing T of the tooth groove is measured from the first signal closing point. i Make a record.

[0038] Preferably, the calculation formula of KL is: KL=(ATL+BL) / 2, and the length of KL is limited to [0, 2ATL];

[0039] Where: ATL = TSL / TS; TS is the number of tooth groups, which refers to the number of teeth in the saw blade, and has nothing to do with the tooth shape;

[0040] BL is the amount of ablation, which refers to the amount of melting and loss during the welding process.

[0041] Preferably, in a single first knife mode, the first knife is arranged in one and only one tooth groove S. i Department;

[0042] Multiple first cut mode: tooth grooves with Ti>=ATL can be used as the first cut point; when searching for the first tooth, point S1 searches backward for the nearest first cut point; all first cut positions can be used as the second cut positions.

[0043] Preferably, in the case of continuous cutting, the system records the location of the sensor S after the last cutting is completed. i The tool is positioned in the right position and the calculation and feeding are performed quickly without making any judgment on the tooth search. If some positions are selected as non-cutting positions, an additional judgment is required in the tooth search process.

[0044] Preferably, the final cutting length FL 终 The range is [(CL-TN), (CL+TP)], and the actual required cutting length CL is greater than the order required length OL.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] 1. The fully automatic band saw blade cutting system forms a complete feeding, tooth finding and cutting system through a set of laser sensors, high-precision feed wheels and adaptive algorithms. The system solves the problem of difficult and inaccurate manual tooth finding, and improves the efficiency and cutting accuracy of band saw blade cutting. After connecting to the MES and ERP systems, it realizes fully automatic cutting, can automatically determine the saw blade feeding situation, and realizes full-process automatic operation after feeding, which greatly improves the efficiency of the cutting station. At the same time, it can also detect the saw blade tooth tip and timely feedback the saw blade bending, tooth loss, tooth damage and other material problems.

[0047] 2. This fully automatic band saw blade cutting system improves production efficiency, reduces the defective rate of cutting, and improves the real-time nature of orders by optimizing the operating procedures and setting processes and adding a network interface. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 This is a schematic diagram of data collection by the laser sensor of the present invention;

[0049] Figure 2 It is a schematic diagram of the positional relationship among the detection unit, the conveying unit and the cutting unit of the present invention;

[0050] Figure 3 The tooth spacing T actually recorded in the present invention i Schematic diagram;

[0051] Figure 4 For S i , P i and T i Schematic diagram of the position on the band saw blade.

[0052] Figure 5 It is a schematic diagram of the actual cutting position and the expected welding seam position of the first cutting of the present invention;

[0053] Figure 6 It is a schematic diagram of the actual cutting position and the expected welding seam position of the second cutting knife of the present invention.

[0054] In the figure: 1. feed wheel; 2. moving cutter; 3. fixed cutter; 4. driving structure; 5. laser sensor S2; 6. laser sensor S1. DETAILED DESCRIPTION

[0055] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0056] The present invention provides a fully automatic band saw blade cutting system, comprising a detection unit, a conveying unit, a cutting unit and a control unit. The detection unit comprises a group of laser sensors, the laser sensors are used to collect tooth profile data of the band saw blade cut for the first time, and send the collected data to the control unit. The laser sensor is equipped with a high-precision encoder. The data collected by the laser sensor include band saw width b, band saw thickness s, tooth groove depth h, tooth pitch t, ​​front angle α, back angle γ and total tooth quantity w, such as Figure 1 As shown; a group of laser sensors are divided into laser sensor S16 and laser sensor S25, and laser sensor S25 is located above laser sensor S16;

[0057] The conveying unit includes two feeding wheel groups, each feeding wheel group includes two feeding wheels 1, and the conveying unit is located below the detection unit;

[0058] The cutting unit includes a movable cutter 2 and a fixed cutter 3; the movable cutter 2 is driven by a driving structure 4, and the movable cutter 2 is located above the fixed cutter 3; the fixed cutter 3 is fixed in position, the fixed cutter 3 and the movable cutter 2 are in a staggered state, and the side of the fixed cutter 3 away from the conveying unit and the side of the movable cutter 2 close to the conveying unit are in the same plane; the laser sensor S2 is located on the side of the laser sensor S1 close to the fixed cutter 3, and the distance D1 between the side of the movable cutter 2 close to the conveying unit and the laser sensor S1 is fixed, and D1 is usually a fixed value of 185mm. Because the cutter loss and adjustment will have an error of 1-2mm, calibration is required to eliminate and update it.

[0059] The positional relationship diagram of the detection unit, conveying unit and cutting unit is as follows: Figure 2 shown.

[0060] In some embodiments of the present application, the driving structure is a hydraulic driving structure, and under the action of the hydraulic driving structure, the movable cutter can cut the band saw blade.

[0061] The control unit is connected to the detection unit, conveying unit and cutting unit respectively. The control unit uses an adaptive algorithm to calculate the optimal cutting point and length, so that the saw blade length is close to an integer multiple of the length of the tooth group. With the support of basic parameters, it automatically prompts whether the current material is sufficient to complete the order cutting based on the length data converted from weight. At the same time, the saw blade tooth tip is detected to promptly feedback material problems such as saw blade bending, tooth loss, tooth damage, etc.

[0062] The adaptive algorithm is implemented as follows:

[0063] Step 1: Tooth shape learning (input)

[0064] The laser sensor moves to a position about 40% of the vertical depth of the tooth groove, and the tooth spacing T of the tooth groove is measured from the first signal off point. iRecord the alveolar position S1 and tooth pitch T recorded by the laser sensor i , the actually recorded tooth pitch data is different from t, as Figure 3 shown, and when the saw blade moves forward, it moves to the left;

[0065] Step 2: First cut positioning (first tooth search)

[0066] a. The laser sensor identifies STS tooth pitches T of the minimum search tooth pitch number, and confirms the tooth tip point P at the current laser sensor S1 by comparing the tooth pitches i ; i

[0067] b. Search backward from point P i to find the position of the first cut S k , and calculate the distance from P i to the set first cut S k , denoted as FCL; k+1

[0068] c. The nearest first cut distance D2 = D1 - [(FCL + D1) / TSL] * TSL, where TSL is the tooth group length, D1 is the saw blade length, and D1 is much larger than all the tooth group lengths TSL of the saw blade, D1 >> TSL;

[0069] If D2 ≥ KL, the feed length for tooth search and cutting -1: FCL_1 = D2 - KL, where KL is the reserved length, referring to the length reserved forward or backward from point P i ; The calculation formula for KL is: KL = (ATL + BL) / 2, and the length of KL is limited to [0, 2ATL], where: ATL = TSL / TS; TS is the number of tooth groups, which refers to the number of teeth in the saw blade's tooth division cycle and has nothing to do with the tooth shape; BL is the ablation amount, referring to the amount melted and lost during the welding process;

[0070] If D2 < KL, the feed length for tooth search and cutting -1: FCL_1 = D2 + TSL - KL;

[0071] Feed the length of FCL_1, cut the tool, and obtain the first cut at S k , and reserve the cut to the front end of the KL length at P k+1 ;

[0072] Step 3: Output the intermediate length

[0073] d. The total feed number of tooth groups K, K = [(OL - ATL) / TSL], where: OL is the order required length, and ATL is the average tooth pitch, which is the average value of the tooth pitches within a group of tooth groups;

[0074] e. The feed length FL after the first cut is made 首 ​​The calculation formula is: FL 首 =(K-1)*TSL+KL;

[0075] f. After the feed wheel is fed by FL, it will move to the nearest P i Click to stop and record the current FL i ;

[0076] Step 4: Tail knife positioning (second tooth search)

[0077] G. Laser sensor identifies the number of feed tooth groups SKS and the tooth spacing T i , by comparing the tooth spacing T i Confirm the current P at S1 i , record the SKS tooth spacing T of the identification process feed i , the tail knife feed length FL at this time 尾 =FL i +Σ(T i ), assign the current total feed amount to FCL_2, FCL_2 = FL 尾 ;

[0078] D3 is the tail knife P i The distance from the point to the CP point; D3 = D1-[D1 / TSL]*TSL, D3 is greater than TSL and greater than 0; where: the CP point is the point where the cutter is close to the conveying unit;

[0079] Final feed length FL 终 =FL 尾 +D3+KL;

[0080] Enter the loop judgment:

[0081] FL 终 ≥CL-TN, TN is the negative tolerance;

[0082] ——Yes, end the loop and output FL 终 , output refeed amount LFL = FL 终 -FCL_2;

[0083] ——No, FL 终 =FL 尾 +T i ;

[0084] Enter the nested loop judgment:

[0085] FL 终 ≤CL+TP, TP is the positive tolerance

[0086] ——Yes, continue the cycle;

[0087] ——No, an error will be reported, and the error adjustment formula or upper limit of error has been exceeded.

[0088] Single first knife mode, the first knife is set in one and only one tooth groove S i Department;

[0089] Multiple first cut mode: tooth grooves with Ti>=ATL can be used as the first cut point; when searching for the first tooth, point S1 searches backward for the nearest first cut point; all first cut positions can be used as the second cut positions.

[0090] In the case of continuous cutting, the system records the location of the sensor after the last cutting. i The tool is positioned in the right position and the calculation and feeding are performed quickly without making any judgment on the tooth search. If some positions are selected as non-cutting positions, an additional judgment is required in the tooth search process.

[0091] Final cutting length FL 终 The range is [(CL-TN), (CL+TP)], and the actual required cutting length CL is greater than the order required length OL.

[0092] In summary: When the fully automatic band saw blade cutting system is used, a set of laser sensors, high-precision feed wheels and adaptive algorithms are used to form a complete feeding, tooth-finding and cutting system. Laser sensors, high-precision encoders and adaptive algorithms are used to achieve high-precision cutting position determination. With the support of basic parameters, the system will collect tooth shape data for the first cutting of the saw blade, and then calculate and set the best cutting position: the first cutting point and the second cutting point; according to the ERP system or manually input order situation, the adaptive algorithm is used to calculate the best cutting point and length, so that the saw blade length is close to the integer multiple of the length of the tooth group. The laser sensor detects the time statistics and automatically corrects the cutting settings according to the tooth spacing. After connecting to the ERP and MES systems, the operator can directly take the corresponding saw blade from the shelf according to the current cutting blade specifications and put it on the coiling table. The system will automatically prompt whether the current material is sufficient to complete the order cutting according to the length data converted by weight, which greatly reduces the difficulty of employees' operation and reduces the steps of operation. And it can judge whether the employee has taken the material correctly through the process of tooth-finding.

[0093] In addition, this solution calculates the first cut position of the next band saw blade based on the second cut positioning point and cutting point of the previous saw blade, which speeds up the cutting speed (without searching for the first tooth of the next blade) and reduces losses. It is equivalent to searching for teeth three times for cutting two blades. Continuous cutting with the same formula only requires searching for the first cut once for the first blade, and only the second cut is required for subsequent blades.

[0094] This solution improves production efficiency, reduces the defective rate of cutting, and improves the real-time nature of orders by optimizing the operating process and setting process, adding a network interface.

[0095] The contents not described in detail in this specification belong to the prior art known to professional and technical personnel in the field. Although the embodiments of the present invention have been shown and described, it is understood by ordinary technicians in the field that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. A fully automatic band saw blade cutting system, comprising a detection unit, a conveying unit, a cutting unit and a control unit, characterized in that: The detection unit includes a group of laser sensors, which are used to collect tooth profile data of the band saw blade for the first cutting and send the collected data to the control unit; the group of laser sensors is divided into a laser sensor S1 and a laser sensor S2, and the laser sensor S2 is located above the laser sensor S1; The conveying unit includes two groups of feed wheel sets, and each feed wheel set includes two feed wheels. The conveying unit is located below the detection unit; The cutting unit includes a moving cutter and a fixed cutter; The moving cutter is driven by a driving structure, and the moving cutter is located above the fixed cutter; The position of the fixed cutter is fixed. The fixed cutter and the moving cutter are in a staggered state, and the side of the fixed cutter away from the conveying unit and the side of the moving cutter close to the conveying unit are in the same plane; the laser sensor S2 is located on the side of the laser sensor S1 close to the fixed cutter, and the distance D1 between the side of the moving cutter close to the conveying unit and the laser sensor S1 is fixed; The control unit is respectively connected to the detection unit, the conveying unit and the cutting unit. The control unit uses an adaptive algorithm to calculate the optimal cutting point and length, making the saw blade length close to an integer multiple of the tooth group length, and automatically prompting whether the current material is sufficient to complete the order cutting according to the length data converted by weight under the support of basic parameters; The adaptive algorithm is implemented according to the following steps: Step 1. Tooth profile learning (entry) Enter the tooth slot position S1 and tooth spacing T recorded by the laser sensor i ; Step 2. First knife positioning (first tooth search) a. Laser sensor identifies the minimum search pitch number STS tooth spacing T i , confirm the tooth tip point P at the current laser sensor S1 by comparing the tooth spacing i ; b. From P i Look back for the first knife S k The position of P i Distance setting of the first knife S k P k+1 The distance is set as FCL; c. The nearest first knife distance D2 = D1 - [(FCL + D1) / TSL]*TSL, where TSL is the tooth group length, D1 is the saw blade length, and D1 >> TSL; If D2 ≥ KL, the tooth-finding cutting feed length - 1: FCL_1 = D2-KL, where KL is the reserved length, which refers to the length from P during the cutting process. i The length reserved for the point forward or backward; If D2 < KL, the feed length of the tooth search cutting - 1: FCL_1 = D2 + TSL - KL; Feed FCL_1 length, cut with knife, and get S k First cut, reserve incision to P k+1 At the front end of KL length; Step 3. Output the intermediate length d. The total number of feed teeth K, K = [(OL - ATL) / TSL], where: OL is the order - required length, ATL is the average tooth pitch, and it is the average value of the tooth pitches within a group of tooth groups; e. Feed length FL after first cutting 首 The calculation formula is: FL 首 =(K-1)*TSL+KL; f. After the feed wheel is fed by FL, it will move to the nearest P i Click to stop and record the current FL i ; Step 4. Tail knife positioning (second tooth search) G. Laser sensor identifies the number of feed tooth groups SKS and the tooth spacing T i , by comparing the tooth spacing T i Confirm the current P at S1 i , record the SKS tooth spacing T of the identification process feed i At this time, the tail knife feed length FL 尾 =FL i +Σ(T i ), assign the current total feed amount to FCL_2, FCL_2 = FL 尾 ; D3 is the tail knife P i The distance from the point to the CP point; D3 = D1-[D1 / TSL]*TSL, D3 is greater than TSL and greater than 0; where: the CP point is the point where the cutter is close to the conveying unit; Final feed length FL 终 =FL 尾 +D3+KL; Enter the loop judgment: FL 终 ≥CL-TN, TN is the negative tolerance; ——Yes, end the loop and output FL 终 , output refeed amount LFL = FL 终 -FCL_2; —— No, FL 终 = FL 尾 + T i ; Enter the nested loop judgment: FL 终 ≤CL+TP, TP is the positive tolerance - Yes, continue the loop; - No, report an error, exceeding the error adjustment formula or the error upper limit.

2. The fully automatic band saw blade cutting system according to claim 1, characterized in that: The laser sensor is equipped with a high - precision encoder, and the data collected by the laser sensor includes the band saw width b, the band saw thickness s, the tooth groove depth h, the tooth pitch t, the rake angle α, the clearance angle γ and the total number of teeth w.

3. The fully automatic band saw blade cutting system according to claim 1, characterized in that: The driving structure is a hydraulic driving structure; D1 is 185mm.

4. The fully automatic band saw blade cutting system according to claim 2, characterized in that: The laser sensor moves to a position of about 40% of the vertical depth of the tooth groove, and the tooth spacing T of the tooth groove is measured from the first signal off point. i Make a record.

5. The fully automatic band saw blade cutting system according to claim 1, characterized in that: The calculation formula for KL is: KL = (ATL + BL) / 2, and the KL length is limited to [0, 2ATL]; Where: ATL = TSL / TS; TS is the number of tooth groups, which refers to the number of teeth in the saw blade's tooth - dividing cycle and has nothing to do with the tooth profile; BL is the ablation amount, which refers to the amount melted and lost during the welding process.

6. The fully automatic band saw blade cutting system according to claim 1, characterized in that: Single first knife mode, the first knife is set in one tooth groove S only i Department; Multi - first - knife mode: The tooth grooves where Ti >= ATL can all be used as the first - knife cutting points; when searching for the first knife, the S1 point searches backward for the nearest first - knife point; all the first - knife positions can be used as the second - knife positions.

7. The fully automatic band saw blade cutting system according to claim 1, characterized in that: In the case of continuous cutting, the system records the location of the sensor after the last cutting. i The tool is positioned in the right position and the calculation and feeding are performed quickly without making any judgment on the tooth search. If some positions are selected as non-cutting positions, an additional judgment is required in the tooth search process.

8. The fully automatic band saw blade cutting system according to claim 1, characterized in that: The final cutting length FL 终 The range is [(CL-TN), (CL+TP)], and the actual required cutting length CL is greater than the order required length OL.

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