A wire cutting system and cutting method based on diamond wire detection

Abstract

The invention relates to the technical field of stone cutting, and provides a wire cutting system and a cutting method based on diamond wire detection. An image acquisition module and a wire diameter detection module are set to respectively obtain image information and wire diameter of the diamond wire, so as to obtain the actual wear amount of the diamond wire, and the expected value of wear consumption within a cutting cycle is obtained in advance according to the length of the retracted wire and the lifting speed of a workbench. By comparing the actual wear value with the expected value, the wear amount of the diamond wire can be judged in time, so as to adjust the retracted wire length and the workbench speed in time to meet the cutting requirements, thereby effectively controlling the wear rate of the diamond wire and preventing the occurrence of wire breakage, and also achieving the purpose of saving costs and improving stone cutting efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of stone cutting, and in particular to a wire cutting system and a cutting method based on diamond wire detection. Background Art

[0002] The cutting of large stone slabs has gradually begun to use the new diamond wire cutting technology to replace the original marble gang saw. The new diamond wire cutting technology has many advantages, such as extremely high material yield, low energy consumption, good flatness control, and no board pulling phenomenon of the gang saw machine. At present, domestic stone companies are actively developing this cutting technology.

[0003] The new diamond cutting technology is to electroplate a layer of diamond particles on ordinary steel wire, and use the efficient cutting ability of diamond particles to cut stone rough materials into plates. Diamond wire cutting of stone rough materials is a direct participation of the diamond wire retracting and releasing wire (positive and negative) pulling. Due to the thinness of diamond wire, the existing diamond wire cutting system often has improper control of wire wear rate, resulting in excessive wire loss during cutting, low cutting efficiency, and even wire breakage, which can directly cause the stone rough materials to be scrapped. Summary of the invention

[0004] The purpose of the present invention is to provide a wire cutting system and a cutting method based on diamond wire detection, so as to solve the problems of low cutting efficiency and even wire breakage caused by excessive wire wear rate during cutting in the existing stone wire cutting system.

[0005] In a first aspect, the present invention provides a wire cutting system based on diamond wire detection, the wire cutting system is used for stone cutting, and comprises: a workbench, a winding roller, an image acquisition module, a wire diameter detection module and a control unit; the image acquisition module is used to obtain image information of the diamond wire on the winding roller, and the wire diameter detection module is used to detect the wire diameter information of the diamond wire; the control unit is connected to the image acquisition module and the wire diameter detection module respectively, and is configured to obtain the image information and wire diameter information of the diamond wire, and control the retracting and releasing wire length of the diamond wire particles and the lifting and lowering speed of the workbench according to the image information and wire diameter information of the diamond wire;

[0006] Specifically, it includes: determining the length of the retractable wire and the lifting speed of the worktable according to the initial parameter conditions; the initial parameter conditions at least include the hardness and size of the stone block, the wire diameter of the diamond wire and the density of the diamond particles;

[0007] According to the length of the retractable wire and the lifting speed of the worktable, an expected value of wear and consumption within a cutting cycle is obtained;

[0008] Obtaining an actual wear value of the diamond wire after a cutting cycle, and determining a magnitude relationship between the actual wear value and the expected value;

[0009] When the actual wear value is greater than the expected value, the winding roller is controlled to reduce the wire winding and / or the workbench is controlled to reduce the speed until the cutting requirement is met.

[0010] Optionally, the control unit includes: a particle information extraction module, an image processing module and a comparison module;

[0011] The particle information extraction module is used to extract particle feature images from the image information of the diamond wire;

[0012] The image processing module is used to perform grayscale processing on the particle feature image, so as to obtain the particle contour information of the diamond wire, and then obtain the density of the diamond particles;

[0013] The comparison module is used to obtain the density change of diamond particles by comparing the particle feature images of the current cycle with the previous cycle, and to determine the actual wear value of the diamond wire based on the density change of the diamond particles and the wire diameter change of the diamond wire.

[0014] Optionally, the actual wear value of the diamond wire is represented by a wear rate, and the expected value is represented by an expected wear rate;

[0015] The wear rate ≈ (wire diameter change rate + 2×particle density change rate) / 2;

[0016] Among them, the wire diameter change rate refers to the ratio of the wire diameter change of the diamond wire between the current cycle and the previous cycle to the wire diameter limit wear; the particle density change rate refers to the ratio of the density change of the diamond particles between the current cycle and the previous cycle to the density limit change of the diamond particles.

[0017] Optionally, the wire cutting system based on diamond wire detection further includes: a wire bow height detection component, wherein the wire bow height detection component is connected to the control unit, and the control unit is used to obtain the wire bow height and determine whether the cutting requirements are met based on the wire bow height.

[0018] Optionally, the control unit also includes: a pay-out and retractable line length calculation module and a parameter storage module; the parameter storage module is used to store initial parameter conditions, and the pay-out and retractable line length calculation module is used to calculate the pay-out and retractable line length; the control unit is respectively connected to the pay-out and retractable line length calculation module and the stone rough material parameter storage module, and is used to determine the pay-out length according to the initial parameter conditions.

[0019] Optionally, the image acquisition module is an electron microscope, and the wire diameter detection module is an electronic micrometer.

[0020] Optionally, the upper end of the electron microscope is connected to a telescopic mechanism, and the electron microscope is driven to rise and fall by the telescopic mechanism to adjust the focal length of the lens.

[0021] Optionally, a flap mechanism is provided at the lower end of the electron microscope, and the flap mechanism is rotatably disposed under the lens of the electron microscope to protect the lens.

[0022] Optionally, the wire cutting system based on diamond wire detection also includes: a water tank and an air drying device; the water tank is arranged on the side of the upper roller and is located between the roller and the winding roller, and the diamond wire passes through the water tank to clean the attachments on the diamond wire when passing through the water tank; the air drying device is arranged on the side of the water tank away from the roller, and is used to spray gas to air dry the diamond wire.

[0023] In a second aspect, the present invention further provides a wire cutting method based on diamond wire detection, comprising:

[0024] S100, determining the length of the retractable wire and the lifting speed of the worktable according to initial parameter conditions; the initial parameter conditions at least include the hardness and size of the stone block, the wire diameter of the diamond wire and the density of the diamond particles, the wire diameter of the diamond wire is obtained according to the wire diameter information, and the density of the diamond particles is obtained according to the image information of the diamond wire;

[0025] S200, obtaining an expected value of wear and tear within a cutting cycle according to the length of the retractable wire and the lifting speed of the worktable;

[0026] S300, obtaining an actual wear value of the diamond wire after a cutting cycle, and determining a magnitude relationship between the actual wear value and the expected value;

[0027] S400, when the actual wear value is greater than the expected value, control the winding roller to reduce wire reeling and / or control the workbench to reduce speed until the cutting requirement is met.

[0028] Optionally, in step S300, obtaining the actual wear value of the diamond wire after one cutting cycle includes:

[0029] S310, extracting a particle feature image from the image information of the diamond wire;

[0030] S320, performing grayscale processing on the particle characteristic image to obtain particle contour information of the diamond wire, and further obtain the density of the diamond particles;

[0031] S330, by comparing the particle characteristic images of the current cycle with the previous cycle, the density change of the diamond particles is obtained, and the actual wear value of the diamond wire is determined based on the density change of the diamond particles and the wire diameter change of the diamond wire.

[0032] The present invention has at least the following technical effects:

[0033] The wire cutting system and method based on diamond wire detection provided by the present invention respectively obtain image information and wire diameter of the diamond wire by setting an image acquisition module and a wire diameter detection module, thereby obtaining the actual wear amount of the diamond wire, and obtaining the expected value of wear consumption within a cutting cycle in advance according to the length of the retracted and unretracted wire and the lifting speed of the workbench. By comparing the actual wear value with the expected value, the wear amount of the diamond wire can be judged in time, so as to adjust the retracted wire length and the workbench speed in time to meet the cutting requirements. Because the unit density of the number of particles decreases rapidly and the diameter decreases rapidly, it proves that the wear is fast, and the retracted wire amount needs to be reduced (that is, the amount of new wire input is increased) to prevent the risk of wire breakage. If there is no obvious wear, the retracted wire amount can be increased (the amount of new wire input can be reduced) to achieve the purpose of cost saving, or the feeding speed of the workbench can be accelerated, thereby effectively controlling the wear rate of the diamond wire to prevent the occurrence of wire breakage, and at the same time achieving the purpose of improving the stone cutting efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0035] Figure 1 A schematic diagram of the overall structure of a wire cutting system based on diamond wire detection provided by an embodiment of the present invention;

[0036] Figure 2 A partial structural schematic diagram of a wire cutting system based on diamond wire detection provided by an embodiment of the present invention;

[0037] Figure 3 A schematic diagram of a partial structure of a wire cutting system based on diamond wire detection provided by an embodiment of the present invention;

[0038] Figure 4 An electron microscope image of a diamond wire on a winding roller taken by an electron microscope in a wire cutting system based on diamond wire detection provided by an embodiment of the present invention;

[0039] Figure 5 A schematic diagram of the connection of a control unit of a wire cutting system based on diamond wire detection provided by an embodiment of the present invention;

[0040] Figure 6 A schematic diagram of various modules in a control unit of a wire cutting system based on diamond wire detection provided by an embodiment of the present invention;

[0041] Figure 7 A flow chart of a wire cutting method based on diamond wire detection provided by an embodiment of the present invention;

[0042] Figure 8 A specific flow chart of step S300 in a wire cutting method based on diamond wire detection provided by an embodiment of the present invention.

[0043] Icons: 1-electron microscope; 2-telescopic mechanism; 3-flap mechanism; 4-focal length; 5-first winding roller; 6-wire arrangement wheel; 7-diamond wire; 8-electronic dial indicator; 9-control unit; 910-particle information extraction module; 920-image processing module; 930-comparison module; 940-retracting and releasing wire length calculation module; 950-parameter storage module; 10-steering wheel; 11-second winding roller; 12-roller; 13-wire bow line; 14-normal line; 15-stone rough material; 16-partition; 17-circulating water; 18-water tank; 19-air drying device; 20-wire bow height detection component. DETAILED DESCRIPTION

[0044] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than 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.

[0045] Those skilled in the art will understand that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as those generally understood by those skilled in the art in the field to which the present invention belongs. It should also be understood that terms such as those defined in common dictionaries should be understood to have meanings consistent with the meanings in the context of the prior art, and will not be interpreted with idealized or overly formal meanings unless specifically defined as here.

[0046] Those skilled in the art will appreciate that, unless otherwise stated, the singular forms "a", "an", "said" and "the" used herein may also include plural forms. It should be further understood that the term "comprising" used in the specification of the present invention refers to the presence of the features, integers, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof. The term "and / or" used herein includes all or any unit and all combinations of one or more associated listed items.

[0047] The technical solution of the present invention and how the technical solution of the present invention solves the above-mentioned technical problems are described in detail below with specific embodiments.

[0048] Combination Figure 1-Figure 3 as well as Figure 5 As shown, an embodiment of the present invention provides a wire cutting system based on diamond wire detection, which is used for stone cutting and includes: a workbench, a winding roller, an image acquisition module (in this embodiment, an electron microscope 1 can be selected), a wire diameter detection module (in this embodiment, an electronic dial gauge 8 can be selected) and a control unit 9. Among them, the workbench is used to load stone rough materials 15, and the rising speed of the workbench will affect the cutting effect. There are two winding rollers, and the two winding rollers (the first winding roller 5 and the second winding roller 11) are respectively arranged on both sides of the wire cutting system. The stone wire saw is to release a whole diamond wire 7 from the second winding roller 11, and after winding multiple circles on four rollers 12, it passes through the turning wheel 10 and the wire arrangement wheel 6 in turn to the first winding roller 5, and the diamond wire 7 is driven by the roller 12 to cut the stone rough materials 15 through forward and reverse rotation. At the same time, the stone rough materials 15 are lifted and fed through the workbench. The cutting uses circulating water 17 as a processing coolant to take away the powder after cutting.

[0049] In order to monitor the diamond wire so as to adjust the cutting parameters in time, the embodiment of the present invention detects the wire diameter and particle image of the diamond wire 7 by setting an electronic dial gauge 8 and an electron microscope 1. Specifically, the electron microscope 1 is used to obtain the image information of the diamond wire 7 on the winding roller, and the electronic dial gauge 8 is used to detect the wire diameter information of the diamond wire 7. The control unit 9 is electrically connected to the electron microscope 1 and the electronic dial gauge 8, respectively, so that the control unit 9 is configured to obtain the image information and wire diameter information of the diamond wire 7, and control the retracting and releasing wire length of the diamond wire 7 and the lifting and lowering speed of the workbench according to the image information and wire diameter information of the diamond wire 7. It should be noted that the image information of the diamond wire 7 refers to the image of the diamond wire 7 wound on the winding roller taken by the electron microscope 1 (such as Figure 4 as shown).

[0050] Further, controlling the retracting and unretracting length of the diamond wire 7 and the lifting and lowering speed of the workbench according to the image information and the wire diameter information of the diamond wire 7 specifically includes:

[0051] The length of the retractable wire and the lifting speed of the workbench are determined according to the initial parameter conditions; the initial parameter conditions at least include the hardness and size of the stone block 15, the wire diameter of the diamond wire 7, and the density of the diamond particles. The wire diameter of the diamond wire 7 and the density of the diamond particles are the factory parameters of the diamond wire 7, and together with the hardness and size of the stone block 15, they can be pre-input into the control unit 9 for storage and standby. The control unit 9 processes these parameters to obtain a preliminary length of the retractable wire and the lifting speed of the workbench. It should be noted that the initial parameter conditions here refer to the parameter conditions before starting the cutting.

[0052] Optionally, in the embodiment of the present invention, the hardness, size, wire diameter of the diamond wire 7, and density of the diamond particles, the length of the retracting wire, and the lifting speed of the worktable can be modeled, for example, by training the model through cutting experience and a large amount of experimental data, so as to obtain a relatively optimized model, so that in the subsequent direct use of the initial parameter conditions as the input object of the model, the length of the retracting wire and the lifting speed of the worktable can be used as the output object of the model, so that the length of the retracting wire and the lifting speed of the worktable under the initial conditions can be obtained. The specific training process of the model is not specifically limited in this embodiment, and the model data can be stored in the control unit 9 and called when needed.

[0053] According to the length of the pay-off and retractable wire and the lifting speed of the worktable, the expected value of the wear and consumption in a cutting cycle is obtained, that is, the expected value of the wear and consumption in a cutting cycle is predetermined by the pay-off and retractable wire length and the lifting speed of the worktable, so as to serve as a reference for the amount of wear in the actual cutting process. It should be noted that a cutting cycle in this embodiment refers to a pay-off and retractable wire cycle, such as: the diamond wire 7 starts to pay-off from the second winding roller 11, and is taken up by the first winding roller 5 to achieve forward cutting, and after cutting, it is paid off again through the first winding roller 5, and the second winding roller 11 is taken up to achieve reverse cutting (part of the diamond wire remains on the first winding roller 5 to achieve the purpose of renewing the wire), and the process of one forward cutting and one reverse cutting is called a cutting cycle.

[0054] The actual wear value of the diamond wire 7 after a cutting cycle is obtained, and the relationship between the actual wear value and the expected value is determined. By comparing the actual wear value with the expected value of wear consumption, the wear condition of the diamond wire 7 can be determined, thereby determining whether the diamond wire 7 can continue to cut normally. When the actual wear value is greater than the expected value, the winding roller is controlled to reduce the winding and / or the workbench is controlled to reduce the speed until the cutting requirements are met. When the actual wear value is less than the expected value, the stone cutting of the next cutting cycle can be continued without adjusting the relevant parameter conditions.

[0055] It can be understood that when the actual wear value is greater than the expected value, controlling the winding roller to reduce wire winding and / or controlling the workbench to reduce speed is actually a correction of the model based on the wear amount. For example, a correction coefficient is determined based on the wear amount (the specific value is not limited), so that the output result of the model can be adjusted through the correction coefficient to meet the cutting requirements.

[0056] In the specific working process, when the multi-wire cutting equipment is used for cutting stone rough material 15, the winding roller will rotate forward and reverse continuously. When switching between forward and reverse, after winding the wire to a certain length, it will switch to unwinding the wire. During this period, the diameter of the winding roller will keep changing, and there will be a pause time when switching between forward and reverse. During this pause time, the control unit 9 collects the changes in the wire diameter and particles of the diamond wire 7:

[0057] Specifically, the embodiment of the present invention is provided with a retractable electron microscope 1 (a flap mechanism 3 is added to the front end of the microscope), that is, the electron microscope 1 is installed above the winding roller through the telescopic mechanism 2. Since the winding roller is far away from the cutting end and there is a partition 16 between the cutting stone block 15, there is less dust and water mist. After the set monitoring time is reached, the front flap mechanism 3 of the microscope is opened and lowered onto the winding roller. Although the diameter of the winding roller is constantly changing, the microscope is lowered onto the winding roller through the cylinder of the telescopic mechanism 2, so that it has a fixed focal length 4, which is conducive to obtaining clear image information of the surface particles of the diamond wire 7, and then obtaining the change of the surface particles of the diamond wire 7 (wear amount). Since the diameter of the diamond wire 7 is generally only about 0.5 mm, it is easy to have inaccurate focus and blurred photos when shooting at a long distance through a telecentric camera lens.

[0058] At the same time, the embodiment of the present invention measures the wire diameter of the diamond wire 7 by adding an electronic dial gauge 8. The electronic dial gauge 8 is electrically connected to the control unit 9. When the device commutation cycle pauses, the electronic dial gauge 8 is controlled to clamp the diamond wire 7 to measure the diameter (wire diameter) of the diamond wire 7, thereby obtaining the change in the wire diameter (i.e., the amount of wear).

[0059] It can be understood that the actual wear value in the embodiment of the present invention can be the actual wear amount of the current cycle (i.e., how much wear has occurred) or the actual wear rate of the current cycle (i.e., the rate of change of wear); when the actual wear value is characterized by the wear amount, the corresponding expected value is a set expected wear amount; when the actual wear value is characterized by the wear rate, the corresponding expected value is a set expected wear rate.

[0060] Optionally, the wire cutting system based on diamond wire detection also includes: a wire bow height detection component 20, the wire bow height detection component 20 is connected to the control unit 9, and the control unit 9 obtains the height of the wire 13 of the wire bow (i.e., the wire bow height) and determines whether the cutting requirements are met based on the wire bow height. When the wire bow height is greater than the preset value, there will be a risk of wire breakage, so it is necessary to strictly monitor the wire bow height, and adjust the wire bow height by reducing the wire winding and / or lowering the rising speed of the workbench. It should be noted that there is a certain difference between the wire bow line 13 and the normal line 14. The angle of the wire bow line 13 will increase relative to the inclination angle of the normal line 14, and the corresponding height will also increase accordingly.

[0061] The wire cutting system based on diamond wire detection provided by the embodiment of the present invention obtains the image information and wire diameter of the diamond wire 7 by setting an electron microscope 1 and an electronic dial indicator 8 respectively, so as to obtain the actual wear amount of the diamond wire 7, and obtains the expected value of wear consumption within a cutting cycle in advance according to the length of the retracted wire and the lifting speed of the workbench. By comparing the actual wear value with the expected value, the wear amount of the diamond wire 7 can be judged in time, so as to adjust the retracted wire length and the workbench speed in time to meet the cutting requirements. Because the unit density of the number of particles decreases rapidly and the diameter decreases rapidly, it proves that the wear is fast, and the retracted wire amount needs to be reduced (that is, the amount of new wire input is increased) to prevent the risk of wire breakage. If there is no obvious wear, the retracted wire amount can be increased (the amount of new wire input can be reduced) to achieve the purpose of cost saving, or the feed speed of the workbench can be accelerated, thereby effectively controlling the wear rate of the diamond wire to prevent the occurrence of wire breakage, and at the same time achieving the purpose of improving the stone cutting efficiency.

[0062] In some embodiments, Figure 6 As shown, the control unit 9 specifically includes: a particle information extraction module 910 , an image processing module 920 and a comparison module 930 .

[0063] Specifically, the particle information extraction module 910 is used to extract the particle feature image from the image information of the diamond wire 7. The image processing module 920 is used to perform grayscale processing on the particle feature image to obtain the particle contour information of the diamond wire 7, and then obtain the density of the diamond particles, wherein the density of the diamond particles is determined by the size and distribution density of the diamond particles, which is equivalent to the area occupied by the particles per unit area of ​​the diamond wire. The comparison module 930 is used to obtain the density change of the diamond particles by comparing the particle feature images of the current cycle with the previous cycle, and determine the degree of wear of the particles on the surface of the diamond wire 7 according to the density change of the diamond particles and in combination with the wire diameter change of the diamond wire 7.

[0064] In this embodiment, the control unit 9 obtains the particle characteristic image of the diamond wire 7 each time, and performs grayscale processing on the image to obtain the contour information of the diamond wire 7 particles, thereby knowing the size of the particles and the particle density of the diamond wire 7 surface per unit area. By comparing the particle characteristic images of the diamond wire 7 before and after, and combining the change in the wire diameter of the diamond wire 7, the actual wear value of the diamond wire 7 is determined.

[0065] In the embodiment of the present invention, the wear rate is used as an example to represent the actual wear value, and the expected value is represented by the expected wear rate. The specific wear rate calculation formula is as follows:

[0066] Wear rate ≈ (wire diameter change rate + 2 × particle density change rate) / 2;

[0067] The wire diameter change rate refers to the ratio of the wire diameter change of the diamond wire between the current cycle and the previous cycle to the wire diameter limit wear; the particle density change rate refers to the ratio of the density change of the diamond particles between the current cycle and the previous cycle to the density limit change of the diamond particles. The wire diameter limit wear is the difference between the wire diameter of the diamond wire under the initial parameter conditions and the set limit wire diameter, and the density limit change is the difference between the density of the diamond particles under the initial parameter conditions and the set limit particle density. When the limit wire diameter and limit particle density are reached, the diamond wire cannot be cut and needs to be supplemented or replaced with a new wire.

[0068] For example, the wire diameter change rate is divided into 0-100% according to the empirical value (for example, the wire diameter changes from the initial 0.55mm (initial wire diameter) to 0.5mm (limit wire diameter), which represents a wire diameter change rate of 0-100%. For example, if the wire diameter change in a certain period is 0.0005, the corresponding wire diameter change rate is (0.0005 / (0.55-0.5))×100%=1%); similarly, the surface particles of the diamond wire are also divided into 0-100% according to the density change of the particles. Due to the large cutting amplitude and stone texture during the stone wire cutting process, in order to ensure the cutting effect and uninterrupted wire, when the change rate of the surface particle density decreases by 50% compared with the original, it is considered that it can no longer be used. Therefore, the wear rate of the surface particle density ρ per unit time (i.e., the particle density change rate) is 1 / 2 of the wire diameter wear rate (which can be defined by the wire diameter change rate). The actual wear value of the diamond wire 7 can be obtained by the above formula.

[0069] It should be noted that since the diamond wire 7 cutting is achieved by continuously retracting and releasing the wire, the length setting of the retracting and releasing wire directly affects the cutting effect and consumables consumption. The length of the wire is determined by the size of the rough material. For example, if the width of the rough material is 1.6 meters, the thickness of the cutting plate is 20 mm, that is, 80 wires, and the length of each circle on the wire net is 12.5 meters, (1.6 / 0.020)*12.5=1000 meters, the length of the wire is set to 1 times the length of the wire net = 1000 meters, so it is set to 1000 meters. The length of the wire retracting can be set according to past experience with a difference of 20 meters. That is, first pay out 1000 meters of wire, and then retract 980 meters of wire. In each cycle, 20 meters of new wire will be used for cutting. This 20 meters of new wire will be used up after 50 cycles, that is, the reasonable wear rate per cycle is 100% / 50=2% under the premise of keeping the rising speed of the working platform unchanged.

[0070] If the wear rate of the diamond wire 7 is too large (for example, the wire wear rate is set to 2% per cycle, but actually reaches 5%), it means that the cutting force is insufficient and the amount of new wire put in is insufficient. The cycle of the new wire in internal circulation will be changed from 50 cycles to 20 cycles. After 20 cycles, the wire is basically worn out and the diamond coating on the wire is exhausted. The consequence of continuing to work is wire breakage. At this time, the process parameters can be adjusted, such as paying out 1,000 meters of wire and taking up 950 meters of wire per cycle, so that 50 meters of new wire is put into cutting use in each cycle. In this way, the internal circulation update cycle of the new wire is faster, and the cutting ability of the diamond wire 7 for cutting stone rough materials 15 will be enhanced.

[0071] If the wear rate of the diamond wire 7 is not large (for example, the wire wear rate is set to 2% per cycle, but it is actually only 1%), it means that the cutting force is sufficient and the amount of new wire put in can be reduced. For example, the wire take-up length can be changed from 980 meters to 990 meters. That is, the new wire was originally designed to be used up after 50 cycles, but it can actually be used for 100 cycles, with 10 meters of new wire put into cutting each cycle, thereby achieving the goal of reducing wire usage and saving costs.

[0072] The embodiment of the present invention obtains the actual wear value by considering the wire diameter of the diamond wire 7 and the density of the diamond particles together. For example, the overall wire diameter does not change much, but the local wear is serious, thereby avoiding the situation where a single factor makes an inaccurate judgment, because the change in wire diameter alone cannot accurately reflect the actual wear situation, and thus the occurrence of wire breakage cannot be avoided in time, thereby affecting the cutting efficiency.

[0073] In some embodiments, continue to refer to Figure 6 The control unit 9 also includes: a pay-out and retracting line length calculation module 940 and a parameter storage module 950; the parameter storage module 950 is used to store initial parameter conditions, and the pay-out and retracting line length calculation module 940 is used to calculate the pay-out and retracting line length; the control unit 9 is respectively connected to the pay-out and retracting line length calculation module 940 and the parameter storage module of the stone rough material 15, and is used to determine the pay-out length according to the initial parameter conditions.

[0074] In some embodiments, continue to refer to Figures 1 to 3 The upper end of the electron microscope 1 is connected to the telescopic mechanism 2, which is a cylinder. The electron microscope 1 is installed on the piston rod of the cylinder. The cylinder is fixed above the first winding roller 5. Due to the floating property of the gas in the cylinder, the piston rod is driven to move by the floating of the gas, thereby driving the electron microscope 1 to rise and fall, and then the focal length 4 of the lens is adjusted through the telescopic mechanism 2 to ensure that a clear image of the diamond wire 7 can be captured, so that the control unit 9 can process the relevant data of the density and particle size of the diamond particles to obtain the actual wear condition of the diamond wire 7.

[0075] In some embodiments, continue to refer to Figures 1 to 3 The lower end of the electron microscope 1 is provided with a flap mechanism 3, which is rotatably arranged under the lens of the electron microscope 1, and is used to protect the lens when not taking pictures. The flap mechanism 3 is flipped open and the lens is exposed only when taking pictures. Optionally, the flap mechanism 3 can be driven by a cylinder or an electric drive, and the opening or closing of the flap mechanism 3 is controlled by a control unit. The flip mechanism 3 is opened when the electron microscope 1 needs to take pictures, and is closed after taking pictures to protect the lens.

[0076] In some embodiments, continue to refer to Figure 1 and Figure 2The wire cutting system based on diamond wire detection also includes: a water tank 18 and an air drying device 19; the water tank 18 is arranged on the side of the roller 12 above and between the roller 12 and the winding roller. The diamond wire 7 passes through the water tank 18, and the attachments on the diamond wire 7 are cleaned when passing through the water tank 18 to prevent the attachments from affecting the measurement of the wire diameter and the authenticity of the particle image of the diamond wire 7. The air drying device 19 is arranged on the side of the water tank 18 away from the roller 12, and is used to spray gas to air dry the diamond wire 7, so as to prevent the wet diamond wire 7 from affecting the transmission stability of the winding roller, and the wet diamond wire 7 will also have a certain impact on the wire diameter measurement and particle image, which is conducive to improving the calculation accuracy of the wear amount.

[0077] Optionally, in order to avoid the problem of water overflow caused by the diamond wire 7 passing through the water tank 18, the water tank 18 in this embodiment is provided with three positions in sequence along the transmission direction of the diamond wire 7, wherein water is only contained in the middle position, and water is circulated into the middle position through a water pipe, and the two positions on both sides serve as overflow positions, and the diamond wire 7 passes through these three positions in sequence, and the attachments on the diamond wire 7 are cleaned by the water in the middle position. Since the position through which the diamond wire 7 passes cannot be completely sealed and water overflow is likely to occur, the water overflowing from the middle position will flow into the positions on both sides, and will be discharged by setting pipelines at the bottom of the positions on both sides, thereby avoiding the problem of water overflow caused by the diamond wire directly perforating the water tank of a single position, thereby affecting the transmission of the entire diamond wire and the safety of the equipment.

[0078] Based on the same inventive concept, Figure 7 As shown, an embodiment of the present invention further provides a wire cutting method based on diamond wire detection, comprising the following steps:

[0079] S100, determining the length of the retractable wire and the lifting speed of the worktable according to initial parameter conditions; the initial parameter conditions at least include the hardness and size of the stone block, the wire diameter of the diamond wire and the density of the diamond particles, the wire diameter of the diamond wire is obtained according to the wire diameter information, and the density of the diamond particles is obtained according to the image information of the diamond wire.

[0080] S200, based on the length of the retractable wire and the lifting speed of the worktable, obtain the expected value of wear and consumption within a cutting cycle.

[0081] S300, obtaining the actual wear value of the diamond wire after a cutting cycle, and determining the magnitude relationship between the actual wear value and the expected value.

[0082] S400, when the actual wear value is greater than the expected value, the winding roller is controlled to reduce the wire reeling and / or the workbench is controlled to reduce the speed until the cutting requirement is met.

[0083] Alternatively, if Figure 8As shown, in step S300, the actual wear value of the diamond wire after a cutting cycle is obtained, including:

[0084] S310, extracting a particle feature image from the image information of the diamond wire.

[0085] S320, grayscale processing is performed on the particle feature image to obtain particle contour information of the diamond wire, and then the density of the diamond particles is obtained.

[0086] S330, by comparing the particle characteristic images of the current cycle with the previous cycle, the density change of the diamond particles is obtained, and the actual wear value of the diamond wire is determined based on the density change of the diamond particles and the wire diameter change of the diamond wire.

[0087] The wire cutting method based on the detection of diamond wire 7 provided in the embodiment of the present invention determines the actual wear amount of the diamond wire 7 by acquiring the image information and wire diameter of the diamond wire 7, and obtains the expected value of wear consumption within a cutting cycle in advance according to the length of the retracted wire and the lifting speed of the workbench. By comparing the actual wear value with the expected value, the wear amount of the diamond wire 7 can be judged in time, so as to adjust the retracted wire length and the workbench speed in time to meet the cutting requirements. Because the unit density of the number of particles decreases rapidly and the diameter decreases rapidly, it proves that the wear is fast, and the retracted wire amount needs to be reduced (that is, the amount of new wire input is increased) to prevent the risk of wire breakage. If there is no obvious wear, the retracted wire amount can be increased (the amount of new wire input is reduced) to achieve the purpose of cost saving, or the feed speed of the workbench can be accelerated to improve the stone cutting efficiency.

[0088] Those skilled in the art will appreciate that the various operations, methods, steps, measures, and schemes discussed in the present invention may be alternated, modified, combined, or deleted. Further, other steps, measures, and schemes in the various operations, methods, and schemes discussed in the present invention may also be alternated, modified, rearranged, decomposed, combined, or deleted. Further, the steps, measures, and schemes in the prior art that are similar to those disclosed in the present invention may also be alternated, modified, rearranged, decomposed, combined, or deleted.

[0089] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0090] The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0091] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific conditions.

[0092] In the description of this specification, specific features, structures, materials or characteristics may be combined in any one or more embodiments or examples in a suitable manner. It should be understood that although the steps in the flowchart of the accompanying drawings are displayed in sequence as indicated by the arrows, these steps are not necessarily performed in sequence in the order indicated by the arrows. Unless clearly stated herein, there is no strict order restriction on the execution of these steps, and they may be performed in other orders. Moreover, at least a portion of the steps in the flowchart of the accompanying drawings may include multiple sub-steps or multiple stages, and these sub-steps or stages are not necessarily performed at the same time, but may be performed at different times, and their execution order is not necessarily performed in sequence, but may be performed in turn or alternately with other steps or at least a portion of the sub-steps or stages of other steps.

[0093] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A wire cutting system based on diamond wire detection, characterized in that: The wire cutting system is used for stone cutting, and comprises: a workbench, a winding roller, an image acquisition module, a wire diameter detection module and a control unit; the image acquisition module is used to acquire image information of the diamond wire on the winding roller, and the wire diameter detection module is used to detect wire diameter information of the diamond wire; the control unit is connected to the image acquisition module and the wire diameter detection module respectively, and is configured to acquire image information and wire diameter information of the diamond wire, and control the retracting and releasing wire length of the diamond wire and the lifting and lowering speed of the workbench according to the image information and wire diameter information of the diamond wire; Specifically, it includes: determining the length of the retractable wire and the lifting speed of the worktable according to the initial parameter conditions; the initial parameter conditions at least include the hardness and size of the stone block, the wire diameter of the diamond wire and the density of the diamond particles; According to the length of the retractable wire and the lifting speed of the worktable, an expected value of wear and tear in a cutting cycle is obtained; Obtaining an actual wear value of the diamond wire after a cutting cycle, and determining a magnitude relationship between the actual wear value and the expected value; When the actual wear value is greater than the expected value, the winding roller is controlled to reduce the wire reeling and / or the workbench is controlled to reduce the speed until the cutting requirement is met; The control unit includes: a particle information extraction module, an image processing module and a comparison module; The particle information extraction module is used to extract particle feature images from the image information of the diamond wire; The image processing module is used to perform grayscale processing on the particle feature image, so as to obtain the particle contour information of the diamond wire, and then obtain the density of the diamond particles; The comparison module is used to obtain the density change of diamond particles by comparing the particle feature images of the current cycle with the previous cycle, and to determine the actual wear value of the diamond wire based on the density change of the diamond particles and the wire diameter change of the diamond wire.

2. The wire cutting system based on diamond wire detection according to claim 1, characterized in that: The actual wear value of the diamond wire is represented by a wear rate, and the expected value is represented by an expected wear rate; The wear rate ≈ (wire diameter change rate + 2×particle density change rate) / 2; Among them, the wire diameter change rate refers to the ratio of the wire diameter change of the diamond wire between the current cycle and the previous cycle to the wire diameter limit wear; the particle density change rate refers to the ratio of the density change of the diamond particles between the current cycle and the previous cycle to the density limit change of the diamond particles.

3. The wire cutting system based on diamond wire detection according to claim 1, characterized in that: Also includes: A wire bow height detection component is connected to the control unit, and the control unit is used to obtain the wire bow height and determine whether the cutting requirements are met based on the wire bow height.

4. The wire cutting system based on diamond wire detection according to claim 3, characterized in that: The control unit further comprises: a retractable line length calculation module and a parameter storage module; the parameter storage module is used to store initial parameter conditions, and the retractable line length calculation module is used to calculate the retractable line length; The control unit is connected to the pay-off and retracting line length calculation module and the stone material parameter storage module respectively, and is used to determine the pay-off and retracting line length according to the initial parameter conditions.

5. The wire cutting system based on diamond wire detection according to any one of claims 1 to 4, characterized in that: The image acquisition module is an electron microscope; and / or the wire diameter detection module is an electronic dial indicator.

6. The wire cutting system based on diamond wire detection according to claim 5, characterized in that: The upper end of the electron microscope is connected to a telescopic mechanism, and the electron microscope is driven to rise and fall by the telescopic mechanism to adjust the focal length of the lens.

7. The wire cutting system based on diamond wire detection according to claim 6, characterized in that: A flap mechanism is arranged at the lower end of the electron microscope, and the flap mechanism is rotatably arranged under the lens of the electron microscope to protect the lens.

8. The wire cutting system based on diamond wire detection according to claim 1, characterized in that: Also includes: A water trough and an air-drying device; the water trough is arranged on the side of the upper roller and is located between the roller and the winding roller. The diamond wire passes through the water trough and the attachments on the diamond wire are cleaned when passing through the water trough; the air-drying device is arranged on the side of the water trough away from the roller and is used to spray gas to air-dry the diamond wire.

9. A wire cutting method based on diamond wire detection, characterized in that: The wire cutting method comprises: S100, determining the length of the retractable wire and the lifting speed of the worktable according to initial parameter conditions; the initial parameter conditions at least include the hardness and size of the stone block, the wire diameter of the diamond wire and the density of the diamond particles, the wire diameter of the diamond wire is obtained according to the wire diameter information, and the density of the diamond particles is obtained according to the image information of the diamond wire; S200, obtaining an expected value of wear and tear within a cutting cycle according to the length of the retractable wire and the lifting speed of the worktable; S300, obtaining an actual wear value of the diamond wire after a cutting cycle, and determining a magnitude relationship between the actual wear value and the expected value; S400, when the actual wear value is greater than the expected value, controlling the winding roller to reduce wire reeling and / or controlling the workbench to reduce speed until the cutting requirement is met; In step S300, obtaining the actual wear value of the diamond wire after a cutting cycle includes: S310, extracting a particle feature image from the image information of the diamond wire; S320, performing grayscale processing on the particle characteristic image to obtain particle contour information of the diamond wire, and further obtain the density of the diamond particles; S330, by comparing the particle characteristic images of the current cycle with the previous cycle, the density change of the diamond particles is obtained, and the wear degree of the particles on the surface of the diamond wire is determined based on the density change of the diamond particles and the change of the wire diameter of the diamond wire.

Images