Material-saving cutting method for simple special-shaped stone by using diamond wire saw

Abstract

According to the material-saving cutting method for the simple special-shaped stone through the diamond wire saw, the robot wire saw is used for cutting and separating the stone into small modules, and then the small modules are combined into a new product, so that the stone is saved, and stone waste is reduced; the cutting method comprises the following steps: step 1, selecting a blank of a to-be-cut piece; 2, on the basis of the selected to-be-cut piece blank, proper modeling and cutting track design are carried out according to requirements; step 3, programming the planned track by using robot offline programming software, constructing a straight line cylindrical surface, and exporting a cutting program; 4, the robot rope saw is started, a cutting program is imported, and the to-be-cut piece blank is cut; 5, after cutting is completed, the to-be-cut piece blank is cut and separated into four separation modules through cutting; step 6, cutting n to-be-cut piece blanks with the same size to form 4n separation modules; and step 7, selecting four small separation modules, and gluing through gluing surfaces to form the special-shaped stone product.

Description

Technical Field

[0001] The present invention belongs to the technical field of stone processing. Specifically, it is a new processing method using a heavy-duty industrial robot to build a stone cutting wire saw mechanism system, and particularly relates to a material-saving cutting method for simple special-shaped stones using a diamond wire saw. Background Art

[0002] Due to the characteristics of strong stability, corrosion resistance, and high hardness of stone materials, and rare stones being relatively precious. Special-shaped stone products have extensive applications in traditional culture and art, home decoration, and construction projects.

[0003] For the processing and manufacturing of special-shaped stone products, by reasonable shaping and layout, using a water jet or wire saw for cutting can significantly improve the material utilization rate. However, when using a water jet for cutting, due to limitations in parameters such as the model of the water jet cutting machine, water jet pressure, cutting speed, cutting angle, and cutting material, the cutting depth can only reach 5 mm to 200 mm, while the cutting width of a wire saw can reach several meters, mainly determined by the width of the equipment and the motor power, etc. However, the traditional diamond wire saw has low processing freedom and is limited in the processing of three-dimensional special-shaped stone products.

[0004] Robots have the characteristics of high freedom and high flexibility. Using a robot wire saw for cutting can solve the problem of processing three-dimensional special-shaped stone products.

[0005] Stone is a non-renewable resource. Improving the utilization rate of stone is of great significance. Conventionally, in order to improve the material utilization rate, reasonable layout and nesting of multiple products are carried out before processing and manufacturing, but there is still a large amount of material waste and loss in this way. Summary of the Invention

[0006] In order to solve the problems of waste in the processing of special-shaped stones and improve the processing efficiency of special-shaped stone products, the present invention provides a new wire saw cutting processing method for specific special-shaped stones to achieve the goals of material saving and high efficiency.

[0007] In order to solve the above technical problems, the present invention provides a material-saving cutting method for simple special-shaped stones using a diamond wire saw. The cutting equipment uses a robot wire saw, and the cutting method includes the following steps:

[0008] Step 1: Selection of the blank of the workpiece to be cut. Select a suitable square blank stone and measure and determine its size;

[0009] Step 2: Based on the selected blank of the workpiece to be cut, carry out appropriate shaping and cutting trajectory design according to requirements. Plan the trajectory line in the xy or xz or yz two-dimensional plane as the directrix of the separating cylinder surface. The planned trajectory line is the cutting trajectory, and the designed cutting trajectories are interconnected and cooperate with each other;

[0010] Step 3: Use robotic offline programming software to program the planned trajectory, construct a separating surface for cutting along the planned trajectory, use the two-dimensional plane where the trajectory line planned in Step 2 is located as the base plane, use the cutting trajectory as the guiding directrix, construct a ruled surface cylinder, and perform wire saw cutting simulation in the offline programming software. After the simulation is correct, export the cutting program;

[0011] Step 4: Start the robotic wire saw, import the cutting program, and perform cutting on the blank of the workpiece to be cut; the robotic wire saw performs longitudinal cutting on the front, back, left, and right of the blank of the workpiece to be cut, with a total of two cuts;

[0012] Step 5: After cutting, cut and separate the blank of the workpiece to be cut into 4 separating modules. Among the 4 side surfaces of the front, back, left, and right of each separating module, there are 2 specially-shaped separating surfaces formed by cutting, and 2 side surfaces are the original side surfaces of the blank of the workpiece to be cut; the specially-shaped separating surface or the original side surface of the blank of the workpiece to be cut serves as the gluing surface;

[0013] Step 6: Perform cutting on n blanks of workpieces to be cut of the same size using the same cutting program to form 4n separating modules;

[0014] Step 7: Select 4 small separating modules according to requirements from the 4n separating modules. The 4 selected small separating modules should be of different shapes from each other. Glue the 4 selected separating modules through the gluing surface to form a specially-shaped stone product; polish the formed specially-shaped stone product to become the final specially-shaped stone product;

[0015] Or Step 7: Select 4 small separating modules according to requirements from the 4n separating modules. The 4 selected small separating modules should be of different shapes from each other. Polish the 4 selected separating modules respectively, and then glue the 4 polished separating modules through the gluing surface to form a specially-shaped stone product.

[0016] In a preferred embodiment, in Step 1, the 4 side surfaces of the selected square blank are flat surfaces.

[0017] In a preferred embodiment, in Step 3, the cutting trajectory is a curve, and the ruled surface cylinder is a surface formed by a group of parallel lines moving along the curve.

[0018] In a preferred embodiment, the group of parallel lines are generatrices, the direction of the generatrices is perpendicular to the base plane, and intersects with the cutting trajectory.

[0019] In a preferred embodiment, in Step 3, the wire saw cutting simulation includes interference detection simulation, collision simulation, and over-cutting simulation.

[0020] In a preferred embodiment, the robotic wire saw includes a robotic arm and a robotic arm turntable, and a wire saw mechanism is connected to the end of the robotic arm through a quick-change chuck;

[0021] The wire saw mechanism includes a frame, a motor drive device, a closed-loop diamond beaded wire, and a diamond beaded wire tensioning device; the frame includes a drive wheel, a tensioning wheel, and two guide wheels, the motor drive device is connected to the drive wheel, and the diamond beaded wire tensioning device is connected to the tensioning wheel;

[0022] The closed-loop diamond beaded wire is wound around the drive wheel, the tensioning wheel, and the guide wheels, and circulates under the drive of the motor drive device; the workpiece blank to be cut is placed between the two guide wheels, and the closed-loop diamond beaded wire is used to cut the workpiece blank to be cut.

[0023] In a preferred embodiment, in step 5, the following steps are included:

[0024] Step a: Clamp the workpiece blank to be cut at the center of the robotic arm turntable;

[0025] Step b: Install and debug the wire saw mechanism at the end of the robotic arm, turn on the equipment system, and import the robotic program of the offline programming to cut the workpiece blank to be cut;

[0026] Step c: Adjust the tension of the tensioning wheel through the diamond beaded wire tensioning device to make the closed-loop diamond beaded wire taut;

[0027] Step d: Turn on the cutting coolant of the wire saw mechanism, turn on the motor drive device, make the closed-loop diamond beaded wire rotate at high speed and be in a stable working state, and then run the imported cutting program;

[0028] Step e: The closed-loop diamond beaded wire performs two longitudinal cuts on the front and back, left and right of the workpiece blank to be cut respectively. After each cut, the closed-loop diamond beaded wire needs to retract along the cutting trajectory and then perform the next cut.

[0029] In a preferred embodiment, in step 7, the selected 4 small separation modules can be joined together through their respective separation surfaces to form a square blank of the original workpiece blank to be cut.

[0030] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0031] 1. The present invention adopts a new processing method for special-shaped stone products. The products are cut and separated into small modules by a robotic wire saw and then combined into new products. This not only saves stone materials and reduces stone waste, but also greatly shortens the processing time. In addition, when combining small separated modules, stones of different materials and colors can be used for combination to form products, meeting the personalized customization needs of different customers.

[0032] 2. Additionally, traditional wire saw processing methods cannot complete special-shaped stone products with grooves. However, by using the processing method proposed in the present invention, it is possible to cut the conical surface and then separate it into small modules for combination to form special-shaped stone products with groove features. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 Three-dimensional cutting diagram of the robotic wire saw in the preferred embodiment of the present invention;

[0034] Figure 2 Three-dimensional diagram of the separation module combination process in the preferred embodiment of the present invention;

[0035] Figure 3 Top view schematic diagram of the separation module combination process in the preferred embodiment of the present invention;

[0036] Figure 4 Generation principle of the separation cylindrical surface in the preferred embodiment of the present invention;

[0037] Figure 5 Actual cutting and splicing process in the preferred embodiment of the present invention;

[0038] Figure 6 Special-shaped stone product after splicing with the special-shaped separation surface of the blank of the workpiece to be cut as the gluing and splicing surface in the preferred embodiment of the present invention;

[0039] Figure 7 Special-shaped stone product after splicing with the original side surface of the blank of the workpiece to be cut as the gluing and splicing surface in the preferred embodiment of the present invention;

[0040] Figure 8 Flowchart summary diagram of the material-saving cutting method implementation in the preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0041] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0042] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by terms such as "upper", "lower", "inner", "outer", "top / bottom end", etc. is based on the orientation or positional relationship shown in the drawings. It is 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 thus should not be construed as a limitation to the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0043] In the description of the present invention, it should be noted that unless otherwise clearly specified and limited, terms such as "installation", "equipped with", "sheathed / connected", "connection", etc. should be understood in a broad sense. For example, "connection" can be a wall-mounted connection, a detachable connection, or an integral connection. It can be a mechanical connection or an electrical connection. It can be directly connected or indirectly connected through an intermediate medium. It can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0044] As Figure 1 , this embodiment provides a material-saving cutting method for diamond wire saws on simple special-shaped stones. The equipment used is a robotic wire saw. The robotic wire saw is on a KUKA robotic arm, and the cutting actuator at the end is a wire saw mechanism. The wire saw mechanism includes a frame, a motor drive device, a closed-loop diamond beaded wire, a diamond beaded wire tensioning device, and a quick-change disc connection device. The wire saw mechanism is connected to the end of the robotic arm through a quick-change disc. There are 4 wheels on the frame of the wire saw mechanism, including 1 drive wheel, 1 tensioning wheel, and 2 guide wheels. The motor drive device is connected to the drive wheel, the diamond beaded wire tensioning device is connected to the tensioning wheel, and the closed-loop diamond beaded wire is wound around the drive wheel, the tensioning wheel, and the guide wheels and circulates under the drive of the motor drive device.

[0045] The drive wheel is driven to rotate by the motor drive device, and the tensioning wheel and the guide wheels are driven to rotate at high speed by the diamond beaded wire. The diamond beaded wire tensioning device includes a hydraulic device. The tensioning wheel can realize the tensioning effect on the diamond beaded wire under the action of the hydraulic device. The workpiece blank to be cut is placed between the two guide wheels, and the diamond beaded wire rotating at high speed can realize the cutting of the workpiece blank to be cut and achieve the cutting separation of the cutting body (as Figure 1 ).

[0046] For the robotic wire saw equipment mentioned in this embodiment, the specific equipment structure and equipment processing method can refer to the wire saw robot equipment and its processing method for three-dimensional stone surface processing with the publication number CN113232172A and the invention name, and will not be introduced in detail in this embodiment.

[0047] The specific implementation steps of the material-saving cutting method of diamond wire saw for simple special-shaped stones are as follows (the flow chart of the whole cutting method implementation is summarized as Figure 8 shown):

[0048] Step 1: Selection of the blank of the workpiece to be cut. Select a suitable square blank stone and measure and determine its size. The front, back, left, and right four sides of the selected square blank are flat surfaces. The front, back, left, and right four sides of the blank are required to have a certain flatness, which is convenient for directly splicing and gluing the cut stones to construct its shape;

[0049] Step 2: Based on the selected blank of the workpiece to be cut, design a suitable shape and cutting trajectory according to requirements. Plan the trajectory line in the xy or xz or yz two-dimensional plane as the directrix of the separating cylinder surface. The planned trajectory line is the cutting trajectory. The trajectory design requires coupling, that is, the designed cutting trajectories are interrelated and cooperate with each other, which is convenient for the subsequent splicing and combination shaping of the cutting (the splicing and combination shaping is such as Figure 2 , Figure 3 );

[0050] Step 3: Use the robot offline programming software to program the planned trajectory, and construct the separating surface (i.e., the separating cylinder surface) for cutting according to the planned trajectory. The specific construction principle is as Figure 4 . Take the two-dimensional plane where the trajectory line planned in Step 2 is located as the base surface (i.e., the trajectory planning surface). The cutting trajectory 1 is a curve. Take the curve as the guiding directrix of the ruled cylinder surface, and construct the ruled cylinder surface 2;

[0051] The ruled cylinder surface is a curved surface formed by a group of parallel straight lines moving along the curve. A group of parallel straight lines is the generatrix 3. The direction of the generatrix 3 (i.e., the corresponding z vector or y vector or x vector) is perpendicular to the base surface and intersects with the cutting trajectory;

[0052] The created separating surface is the separating cylinder surface, and perform wire saw cutting simulation in the offline programming software. The wire saw cutting simulation includes interference detection simulation, collision simulation, and overcut simulation. Simulate and detect problems such as interference, collision, and overcut. After the simulation is correct, export the cutting program;

[0053] Step 4: Start the robot wire saw, import the cutting program, and perform cutting on the blank of the workpiece to be cut. The robot wire saw performs longitudinal cutting from the front, back, left, and right of the blank of the workpiece to be cut, for a total of two cuts (such as Figure 1 );

[0054] In Step 4, the cutting process of the robot wire saw includes the following steps:

[0055] Step a: Clamp the blank of the workpiece to be cut at the center of the robotic arm turntable;

[0056] Step b: Install and debug the wire saw mechanism at the end of the robotic arm, turn on the equipment system, import the robot program of offline programming, and cut the blank of the workpiece to be cut;

[0057] Step c: Adjust the tension of the tensioning wheel through the diamond beaded wire tensioning device to make the closed-loop diamond beaded wire taut;

[0058] Step d: Turn on the cutting coolant of the wire saw mechanism, turn on the motor drive device, make the closed-loop diamond beaded wire rotate at high speed and be in a stable working state, and then run the imported cutting program;

[0059] Step e: The closed-loop diamond beaded wire makes two longitudinal cuts on the front, back, left, and right of the blank of the workpiece to be cut (original blank) respectively. After each cut, the closed-loop diamond beaded wire needs to retract along the cutting trajectory and then proceed with the next cut (such as Figure 5 actual cutting).

[0060] Step 5: After cutting, cut and separate the blank of the workpiece to be cut into 4 separation modules (such as Figure 3 ). Among the 4 side faces of the front, back, left, and right of each separation module, there are 2 specially-shaped separation faces formed by cutting, and 2 side faces are the original side faces of the blank of the workpiece to be cut; The specially-shaped separation face or the original side face of the blank of the workpiece to be cut serves as the bonding surface 4, specifically as shown in Figure 6 , Figure 7 identification;

[0061] Step 6: Cut n blanks of the workpiece to be cut of the same size using the same cutting program to form 4n separation modules;

[0062] Specifically, for blank cuttings of the same size and the same trajectory type, batch cutting is carried out for multiple times and various types of stones to form a series of a batch of small separation modules. After cutting n blank cuttings, 4n stone separation small modules will be formed;

[0063] Step 7: Select 4 small separation modules according to requirements from the 4n separation modules. The 4 selected small separation modules should be of different shapes from each other. Glue the 4 selected separation modules through the bonding surface to form a specially-shaped stone product; Grind and polish the formed specially-shaped stone product to become the final specially-shaped stone product (such as Figure 5 );

[0064] Or Step 7: Select 4 small separation modules according to requirements from the 4n separation modules. The 4 selected small separation modules should be of different shapes from each other. Grind and polish the 4 selected separation modules respectively, and then glue the 4 selected separation modules through the bonding surface to form a specially-shaped stone product (such as Figure 5 );

[0065] Among them, the selected 4 small separation modules can be joined together through their respective separation surfaces to form a square blank of the original workpiece to be cut (such as Figure 2 or Figure 5 ).

[0066] This embodiment provides a material-saving cutting method for simple special-shaped stones by a diamond wire saw, and the beneficial effects are as follows:

[0067] 1. Save stones and reduce stone waste: By reasonable shape layout and cutting trajectory design, the workpiece blank to be cut is cut and separated into multiple separation modules, and then combined and spliced, making full use of the stone material and avoiding a large amount of material waste in traditional processing methods.

[0068] 2. Improve processing efficiency: Using a robot wire saw for cutting, which has the characteristics of high freedom and high flexibility, can quickly and accurately complete complex cutting tasks, greatly shortening the processing time.

[0069] 3. Meet the needs of personalized customization: When combining small separation modules, stones of different materials and colors can be used for combination to form special-shaped stone products with different shapes and styles, meeting the personalized customization needs of different customers.

[0070] 4. Realize the processing of complex special-shaped stone products: Traditional wire saw processing methods cannot complete special-shaped stone products with complex features such as grooves, while the processing method proposed in the present invention can realize cutting the conical surface and then cutting and separating it into small modules, and combining them into special-shaped stone products with groove features, broadening the application range of stone processing.

[0071] The above is only a preferred specific embodiment of the present invention, but the design concept of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention who makes non-substantive modifications to the present invention using this concept shall fall within the scope of infringement of the protection of the present invention.

Claims

1. A material-saving cutting method for simple special-shaped stone materials by a diamond wire saw, characterized in that: The cutting equipment uses a robotic wire saw, and the cutting method includes the following steps: Step 1: Selection of the blank of the workpiece to be cut. Select a suitable square blank stone and measure and determine its size; Step 2: Based on the selected blank of the workpiece to be cut, perform appropriate shaping and cutting trajectory design according to requirements. Plan the trajectory line in the xy or xz or yz two-dimensional plane as the directrix of the separating cylinder surface. The planned trajectory line is the cutting trajectory, and the designed cutting trajectories are interrelated and cooperate with each other; Step 3: Use robotic offline programming software to program the planned trajectory, construct the separating surface for cutting with the planned trajectory. Take the two-dimensional plane where the trajectory line in Step 2 is located as the base surface, use the cutting trajectory as the guiding directrix, construct a ruled surface cylinder, and perform wire saw cutting simulation in the offline programming software. After the simulation is correct, export the cutting program; Step 4: Start the robotic wire saw, import the cutting program, and cut the blank of the workpiece to be cut; the robotic wire saw performs longitudinal cutting from the front, back, left, and right of the blank of the workpiece to be cut, with a total of two cuts; Step 5: After cutting, cut and separate the blank of the workpiece to be cut into 4 separation modules. Among the 4 side surfaces of the front, back, left, and right of each separation module, there are 2 specially-shaped separating surfaces formed by cutting, and 2 side surfaces are the original side surfaces of the blank of the workpiece to be cut; the specially-shaped separating surface or the original side surface of the blank of the workpiece to be cut is used as the gluing surface; Step 6: Cut n blanks of the workpiece to be cut with the same size using the same cutting program to form 4n separation modules; Step 7: Select 4 small separation modules according to requirements from the 4n separation modules. The 4 selected small separation modules should be of different shapes from each other. Glue the selected 4 separation modules through the gluing surface to form a specially-shaped stone product; grind and polish the formed specially-shaped stone product to become the final specially-shaped stone product; Or Step 7: Select 4 small separation modules according to requirements from the 4n separation modules. The 4 selected small separation modules should be of different shapes from each other. Grind and polish the selected 4 separation modules respectively, and then glue the selected 4 separation modules through the gluing surface to form a specially-shaped stone product.

2. The material-saving cutting method of a diamond wire saw for simple special-shaped stone materials according to claim 1, characterized in that: In Step 1, the 4 side surfaces of the selected square blank are flat surfaces.

3. A method for material-saving cutting of simple special-shaped stone materials by a diamond wire saw according to claim 1, characterized in that: In Step 3, the cutting trajectory is a curve, and the ruled surface cylinder is a surface formed by a group of parallel straight lines moving along the curve.

4. A method for material-saving cutting of simple special-shaped stone materials by a diamond wire saw according to claim 3, characterized in that: The group of parallel straight lines is the generatrix, and the direction of the generatrix is perpendicular to the base surface and intersects with the cutting trajectory.

5. A material-saving cutting method for simple shaped special stones by a diamond wire saw according to claim 1, characterized in that: In Step 3, the wire saw cutting simulation includes interference detection simulation, collision simulation, and overcut simulation.

6. The material-saving cutting method of a diamond wire saw for simple special-shaped stone materials according to claim 1, characterized in that: The robotic wire saw includes a robotic arm and a robotic arm turntable. The end of the robotic arm is connected with a wire saw mechanism through a quick-change disk; The wire saw mechanism includes a frame, a motor drive device, a closed-loop diamond beaded wire, and a diamond beaded wire tensioning device; the frame includes a driving wheel, a tensioning wheel, and two guiding wheels. The motor drive device is connected with the driving wheel, and the diamond beaded wire tensioning device is connected with the tensioning wheel; The closed-loop diamond beaded wire winds around the driving wheel, the tensioning wheel and the guiding wheel, and circulates under the drive of the motor driving device; the workpiece blank to be cut is placed between the two guiding wheels, and the closed-loop diamond beaded wire is used to cut the workpiece blank to be cut.

7. A material-saving cutting method for simple special-shaped stone by a diamond wire saw according to claim 6, characterized in that: In step 5, the following steps are included: Step a: Clamp the workpiece blank to be cut at the center of the robotic arm turntable. Step b: Install and debug the wire saw mechanism at the end of the robotic arm, turn on the equipment system, and import the robot program programmed offline to cut the workpiece blank to be cut. Step c: Adjust the tension of the tensioning wheel through the diamond beaded wire tensioning device to make the closed-loop diamond beaded wire taut. Step d: Turn on the cutting coolant of the wire saw mechanism, turn on the motor driving device to make the closed-loop diamond beaded wire rotate at high speed and be in a stable working state, and then run the imported cutting program. Step e: The closed-loop diamond beaded wire makes two longitudinal cuts on the front and back, left and right of the workpiece blank to be cut respectively. After each cut, the closed-loop diamond beaded wire needs to retract along the cutting trajectory before proceeding to the next cut.

8. A material-saving cutting method for simple special-shaped stone materials by a diamond wire saw according to claim 1, characterized in that: In step 7, the selected 4 small separation modules can be assembled into a square blank of the original workpiece blank to be cut through their respective separation surfaces.

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