Method for reducing maintenance cost of single crystal rod squaring and cutting mechanism
By casting an annular coating layer on the aluminum alloy substrate and performing multiple grooving processes, cutting wheels and annular wires of different circumferences are formed, which solves the problem of high maintenance costs of the single crystal silicon square cutting mechanism, realizes the reuse of the aluminum alloy substrate and extends the life of the annular wire, and reduces maintenance and replacement costs.
Patent Information
- Application Number
- CN202510802151.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-16
- Publication Date
- 2025-09-12
AI Technical Summary
The existing single crystal silicon squaring and cutting mechanism has high maintenance costs, and the life of the ring wire is fixed, which cannot effectively reduce the replacement cost.
By pouring an annular coating layer on the aluminum alloy substrate and performing multiple grooving processes, cutting wheels and annular wires of different circumferences are formed, thereby enabling the aluminum alloy substrate to be reused and the annular wires of different circumferences to be replaced to match it.
The maintenance cost of the cutting mechanism is greatly reduced, while the processing quality of the square rods and the service life of the ring wire are improved, and the average cost of the ring wire is reduced.
Smart Images
Figure CN120620487A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of single crystal silicon production equipment, and in particular to a method for reducing the maintenance cost of a single crystal rod squaring and cutting mechanism. Background Art
[0002] Currently, squaring machines are widely used to square single-crystal silicon ingots. Before processing, a circular wire is installed in the wire slots of two sets of cutting wheel trains to form a cutting mechanism. The high-speed rotating cutting wheel train drives the circular wire to perform two friction cuts on the single-crystal silicon ingot, dividing the ingot into four edge skins and a square ingot, thus completing the conversion from a round ingot to a square ingot. Compared with traditional diamond wire squaring, the advantages of a squaring machine include: first, high efficiency; second, better control of the extreme deviation of the square ingot's side length.
[0003] Each cutting wheel system consists of four cutting wheels (one drive wheel, two passive cutting wheels, and one tension wheel). Each cutting wheel is composed of an aluminum alloy base and an embedded spacer ring. The spacer ring directly contacts and rubs against the ring wire, replacing the aluminum alloy base in the wear process. The ring wire is made of tungsten wire or carbon steel, braided into a spiral and then electroplated with diamond powder. The following problems may occur during use:
[0004] 1. When the cutting wheel constrains the left and right displacement and jitter of the circular wire to maintain the extreme difference in the side length of the square rod, as the circular wire is used for a longer time, the spacer ring with a hardness lower than diamond wears out more deeply, and its ability to constrain the freedom of the circular wire is weakened, resulting in an increase in the extreme difference in the side length of the square rod and abnormalities such as the circular wire breaking. At this time, it is necessary to knock off the excessively worn spacer ring and then embed a new spacer ring into the aluminum alloy substrate. However, this operation is difficult and time-consuming. In order not to affect the squaring efficiency, the work of embedding the spacer ring is generally outsourced, and maintenance personnel can only choose to replace the cutting wheel with a new one, resulting in excessively high maintenance costs.
[0005] 2. After cutting a certain number of round bars, the ring wire will experience diamond powder shedding or broken edges, significantly reducing its cutting capacity. This will increase the extreme difference in the side length of the square bars and exceed the process control standard. At this time, a new ring wire needs to be replaced. However, regardless of whether the ring wire is new or old, its length is fixed, and the amount of diamond powder electroplated is also relatively fixed, resulting in a relatively fixed service life and the cost of replacement cannot be effectively reduced. Summary of the Invention
[0006] In view of the shortcomings of the existing technology, the present invention provides a method for reducing the maintenance cost of a single crystal rod squaring cutting mechanism, so as to solve the problems that the existing cutting wheel with embedded spacer rings can only be replaced, resulting in excessively high maintenance costs, and the service life of the ring wire is relatively fixed and the replacement cost cannot be effectively reduced.
[0007] To achieve the above objectives, the present invention provides the following technical solutions:
[0008] A method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism comprises the following steps:
[0009] S01. Measure the minimum distance between the existing cutting fluid spray pipe and the outer circle of the aluminum alloy base of the nearest existing cutting wheel to obtain the vertical distance between the existing cutting fluid spray pipe and the rotation center of the nearest existing cutting wheel;
[0010] S02. Casting the aluminum alloy substrates of the eight cutting wheels separately to form an annular coating layer, wherein the outer radius of the annular coating layer is larger than the outer radius of the aluminum alloy substrate and smaller than the vertical distance obtained in S01, and the inner radius of the annular coating layer is smaller than the outer radius of the aluminum alloy substrate so that the front and rear are embedded in the latter;
[0011] S03, performing a first annular grooving process on the annular coating layer formed in S02 according to a predetermined removal amount to obtain eight first cutting wheels having first grooves;
[0012] S04, installing the eight first cutting wheels obtained in S03 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of first cutting wheel trains;
[0013] S05. Measure the swing range of the tension wheel of the first cutting wheel system obtained in S04, produce two first loop wires of a first circumference, and install them in the first wire slots of the two sets of first cutting wheel systems, respectively, to form a first cutting mechanism to square the single crystal ingot;
[0014] S06. After the first cutting wheel and the first annular wire have reached the end of their service life, the first annular wire is discarded, the eight first cutting wheels are removed, and the remaining annular coating layers thereof are subjected to a second annular grooving process according to a predetermined removal amount, thereby removing the worn first wire grooves and obtaining eight second cutting wheels having second wire grooves.
[0015] S07, installing the eight second cutting wheels obtained in S06 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of second cutting wheel trains;
[0016] S08. Measure the swing range of the tension wheel of the second cutting wheel train obtained in S07, make two second loop wires of a second circumference, and install them in the second wire slots of the two sets of second cutting wheel trains, respectively, to form a second cutting mechanism to square the single crystal ingot;
[0017] S09. After the second cutting wheel and the second annular wire have reached the end of their service life, the second annular wire is discarded, the eight second cutting wheels are removed, and the remaining annular coating layers thereof are respectively subjected to a third annular grooving process according to a predetermined removal amount, so as to remove the worn second wire grooves and obtain eight third cutting wheels having third wire grooves;
[0018] S10, installing the eight third cutting wheels obtained in S09 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of third cutting wheel trains;
[0019] S11, measuring the swing range of the tension wheel of the third cutting wheel system obtained in S10, making two third ring wires of a third circumference, and installing them in the third wire slots of the two sets of third cutting wheel systems respectively to form a third cutting mechanism to square the single crystal ingot;
[0020] S12. After the third cutting wheel and the third annular wire have reached their service life, the third annular wire is discarded, the eight third cutting wheels are removed and the remaining annular coating layer is completely removed to retain the aluminum alloy substrate, and then S02 to S11 are repeated.
[0021] In one embodiment disclosed in the present application, the minimum distance in S01 is 8 mm.
[0022] In one embodiment disclosed in the present application, the material of the annular coating layer is polyurethane.
[0023] In one embodiment disclosed in the present application, the outer radius of the aluminum alloy substrate is 125 mm;
[0024] The vertical distance obtained in S01 is 133 mm;
[0025] The outer radius of the annular coating layer is 130 mm and the inner radius is 118 mm;
[0026] The annular coating layer has an annular width of 12 mm.
[0027] In one embodiment disclosed in the present application, the predetermined removal amount is 3 mm.
[0028] In one embodiment disclosed in the present application, the circumference of the first annular line is 3650 mm.
[0029] In one embodiment disclosed in the present application, the circumference of the second annular line is 3630 mm.
[0030] In one embodiment disclosed in the present application, the circumference of the third circular line is 3615 mm.
[0031] Compared with the prior art, the present invention has the following beneficial effects:
[0032] By coating the existing aluminum alloy substrate once and grooving it three times, the aluminum alloy substrate can be reused and the annular wires of different circumferences can be replaced to match it, which can greatly reduce the maintenance cost of the cutting mechanism and sustainably improve and enhance the processing quality of the square bars. BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.
[0034] Figure 1 Schematic diagram of the three-dimensional structure of the cutting mechanism;
[0035] Figure 2 It is a schematic diagram of the main structure of the cutting mechanism;
[0036] Figure 3 Schematic diagram of the main structure of the first to third cutting gear trains;
[0037] Figure 4 for Figure 3 Schematic diagram of the enlarged structure of part A in the middle. DETAILED DESCRIPTION
[0038] Hereinafter, only certain exemplary embodiments are briefly described. As will be appreciated by those skilled in the art, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and description are to be considered as illustrative in nature and not restrictive.
[0039] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying 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 should not be understood as limiting the present invention.
[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature identified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.
[0041] In the present invention, unless otherwise expressly specified or limited, terms such as "mounted," "connected," "connect," and "fixed" should be understood broadly. For example, they may refer to fixed connection, detachable connection, or integration; they may refer to direct connection or indirect connection through an intermediate medium; they may refer to internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.
[0042] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.
[0043] The disclosure below provides many different embodiments or examples to realize different structures of the present invention. In order to simplify the disclosure of the present invention, the parts and settings of specific examples are described below. Of course, they are only examples, and the purpose is not to limit the present invention.
[0044] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.
[0045] See also Figures 1 to 3 As shown, the present invention provides a method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism, comprising the following steps:
[0046] S01. Measure the minimum distance between the existing cutting fluid spray pipe and the outer circle of the aluminum alloy base of the existing cutting wheel closest to it, so as to obtain the vertical distance between the existing cutting fluid spray pipe and the rotation center of the existing cutting wheel closest to it.
[0047] Specifically, the minimum distance between the existing cutting fluid spray pipe 1 and the outer diameter of the aluminum alloy substrate 2 of the nearest existing cutting wheel was measured on-site. This minimum distance, added to the outer radius of the aluminum alloy substrate, gave the vertical distance between the existing cutting fluid spray pipe and the rotational center of the nearest existing cutting wheel. This allowed the theoretical value of the increase in the existing cutting wheel's outer diameter to be determined (i.e., to avoid interference between the rotating cutting wheel and the cutting fluid spray pipe). In this embodiment, this minimum distance was 8 mm.
[0048] S02. The aluminum alloy substrates of the eight cutting wheels are cast separately to form an annular coating layer, the outer radius of the annular coating layer is larger than the outer radius of the aluminum alloy substrate and smaller than the vertical distance obtained in S01, and the inner radius of the annular coating layer is smaller than the outer radius of the aluminum alloy substrate so that the front and rear are embedded in the latter.
[0049] Specifically, polyurethane material is used to cast the annular groove around the aluminum alloy substrate, thereby forming an annular coating layer that is embedded with the aluminum alloy substrate. In this embodiment, the outer radius R of the aluminum alloy substrate is 125 mm, the vertical distance D obtained in S01 is 133 mm, and the outer radius R of the annular coating layer is 133 mm. o 130mm, inner radius R i The annular coating layer has an annular width W (ie, the difference between the inner and outer radii) of 118 mm and an annular coating layer has an annular width W of 12 mm.
[0050] S03 , performing a first annular grooving process on the annular coating layer formed in S02 according to a predetermined removal amount, so as to obtain eight first cutting wheels 3 having first linear grooves 31 .
[0051] S04. Install the eight first cutting wheels obtained in S03 in groups of four and in a rectangular arrangement on the left and right cutting heads of the squarer to obtain two groups of first cutting wheel trains.
[0052] S05. Measure the swing range of the tension wheel of the first cutting wheel system obtained in S04, make two first annular wires 4 of a first circumference, and install them in the first wire slots of the two sets of first cutting wheel systems respectively to form a first cutting mechanism to square the single crystal ingot.
[0053] S06. After the first cutting wheel and the first annular wire have reached the end of their service life, the first annular wire is discarded, the eight first cutting wheels are removed, and the remaining annular coating layers thereof are subjected to a second annular grooving process according to a predetermined removal amount, so as to remove the worn first wire grooves and obtain eight second cutting wheels 5 having second wire grooves 51.
[0054] S07. Install the eight second cutting wheels obtained in S06 in groups of four and in a rectangular arrangement on the left and right cutting heads of the squarer to obtain two sets of second cutting wheel trains.
[0055] S08. Measure the swing range of the tension wheel of the second cutting wheel train obtained in S07, make two second ring wires 6 of a second circumference, and install them in the second wire slots of the two sets of second cutting wheel trains respectively to form a second cutting mechanism to square the single crystal ingot.
[0056] S09. After the second cutting wheel and the second annular wire have reached their service life, the second annular wire is discarded, the eight second cutting wheels are removed, and the remaining annular coating layers thereof are subjected to a third annular grooving process according to a predetermined removal amount, so as to remove the worn second wire grooves and obtain eight third cutting wheels 7 having third wire grooves 71.
[0057] S10. Install the eight third cutting wheels obtained in S09 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of third cutting wheel trains.
[0058] S11. Measure the swing range of the tension wheel of the third cutting wheel system obtained in S10, make two third ring wires 8 of a third circumference, and install them in the third wire slots of the two sets of third cutting wheel systems respectively to form a third cutting mechanism to square the single crystal ingot.
[0059] S12. After the third cutting wheel and the third annular wire have reached their service life, the third annular wire is discarded, the eight third cutting wheels are removed and the remaining annular coating layer is completely removed to retain the aluminum alloy substrate, and then S02 to S11 are repeated.
[0060] Specifically, the predetermined removal amount is determined based on the wear depth of the cutting wheel caused by the annular wire cuts after each end of its service life + the depth of the wire groove. In this embodiment, the predetermined removal amount is 3 mm, representing the depth of each annular groove. Therefore, after the third annular groove, the remaining annular coating layer has a width of 3 mm, effectively protecting the aluminum alloy substrate from wear caused by the annular wire. The first through third wire grooves have a V-shaped cross-section, with a specific angle and depth, and this depth is equal to the predetermined removal amount.
[0061] The following combination Figure 3 and Figure 4 , respectively explaining the changes in specific dimensions of the first to third cutting wheels obtained after three annular grooving processes on the aluminum alloy substrate with an annular coating layer and how the circumferences of the first to third annular lines are determined.
[0062] As can be seen from the figure:
[0063] The theoretical circumference of each ring line = 800*2+630*2+2*π*R n
[0064] Where, the unit of each dimension is mm, 800 and 630 are the center distances between the cutting wheels when the tension wheel is at the tension limit, R n is the radius of the first to third wire slots (where n=1, 2, 3).
[0065] When the outer radius R oWhen a first cutting wheel with a first groove is formed after removing a predetermined amount of 3 mm from a 130 mm annular coating layer during the first annular groove process, the groove bottom radius R1 of the first groove (indicated by the green dashed line in the figure) is 127 mm. The theoretical circumference of the first annular wire is calculated to be 3658 mm using the above formula. Taking into account the oscillation of the tension pulley, the circumference of the first annular wire (indicated by the green solid line in the figure) is set to 3658 mm in this embodiment.
[0066] When the first cutting wheel removes the worn first grooves by a predetermined amount of 3 mm during the second annular grooving process, resulting in a second cutting wheel with second grooves, the groove bottom radius R2 of the second groove (indicated by the yellow dashed line in the figure) is 124 mm. The theoretical circumference of the second annular line is calculated as 3639 mm according to the above formula. Taking into account the swinging effect of the tension pulley, in this embodiment, the circumference of the second annular line (indicated by the yellow solid line in the figure) is set to 3630 mm.
[0067] When the second cutting wheel, after the third annular grooving process, removes the worn second groove by a predetermined amount of 3 mm, resulting in a third cutting wheel with third grooves, the groove bottom radius R3 of the third groove (indicated by the red dashed line in the figure) is 121 mm. The theoretical circumference of the third annular line is calculated as 3620 mm according to the above formula. Taking into account the swinging effect of the tension pulley, in this embodiment, the circumference of the third annular line (indicated by the red solid line in the figure) is set to 3615 mm (the same as in conventional use).
[0068] The three types of circular wires with different circumferences were tested on the machine respectively. It has been verified that the maintenance cost of the existing aluminum alloy substrate that is first coated and then grooved multiple times has decreased by 40% on the basis of the existing "outsourcing + replacement". Replacing the circular wires with different circumferences to match them can make the squaring and cutting process more stable, the extreme difference in the side length of the square rod is 0.1 to 0.2 mm smaller than the original design, and the silicon consumption is reduced by 50%; although the circumference of the circular wires used in the first two squarings is longer than that used currently, the amount of diamond micropowder involved in the cutting has increased, the cutting capacity has been enhanced, and its service life has been extended accordingly. In summary, the average cost of the circular wires used in the three squarings has decreased by 32% on the basis of the existing replacement. Through the above methods, the maintenance cost of the cutting mechanism can be reduced by more than 160,000 yuan per year.
[0069] In summary, by coating the existing aluminum alloy substrate once and grooving it three times, the aluminum alloy substrate can be reused, and the annular wires of different circumferences can be replaced to match it, which can greatly reduce the maintenance cost of the cutting mechanism and sustainably improve and enhance the processing quality of the square bar.
[0070] The above embodiments are only preferred embodiments of the present invention and are not limitations on the technical solutions of the present invention. Any technical solution that can be implemented on the basis of the above embodiments without creative work should be deemed to fall within the scope of protection of the patent of the present invention.
Claims
1. A method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism, characterized in that: The following steps are involved: S01. Measure the minimum distance between the existing cutting fluid spray pipe and the outer circle of the aluminum alloy base of the nearest existing cutting wheel to obtain the vertical distance between the existing cutting fluid spray pipe and the rotation center of the nearest existing cutting wheel; S02. Casting the aluminum alloy substrates of the eight cutting wheels separately to form an annular coating layer, wherein the outer radius of the annular coating layer is larger than the outer radius of the aluminum alloy substrate and smaller than the vertical distance obtained in S01, and the inner radius of the annular coating layer is smaller than the outer radius of the aluminum alloy substrate so that the front and rear are embedded in the latter; S03, performing a first annular grooving process on the annular coating layer formed in S02 according to a predetermined removal amount to obtain eight first cutting wheels having first grooves; S04, installing the eight first cutting wheels obtained in S03 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of first cutting wheel trains; S05. Measure the swing range of the tension wheel of the first cutting wheel system obtained in S04, produce two first loop wires of a first circumference, and install them in the first wire slots of the two sets of first cutting wheel systems, respectively, to form a first cutting mechanism to square the single crystal ingot; S06. After the first cutting wheel and the first annular wire have reached the end of their service life, the first annular wire is discarded, the eight first cutting wheels are removed, and the remaining annular coating layers thereof are subjected to a second annular grooving process according to a predetermined removal amount, thereby removing the worn first wire grooves and obtaining eight second cutting wheels having second wire grooves. S07, installing the eight second cutting wheels obtained in S06 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of second cutting wheel trains; S08. Measure the swing range of the tension wheel of the second cutting wheel train obtained in S07, make two second loop wires of a second circumference, and install them in the second wire slots of the two sets of second cutting wheel trains, respectively, to form a second cutting mechanism to square the single crystal ingot; S09. After the second cutting wheel and the second annular wire have reached the end of their service life, the second annular wire is discarded, the eight second cutting wheels are removed, and the remaining annular coating layers thereof are respectively subjected to a third annular grooving process according to a predetermined removal amount, so as to remove the worn second wire grooves and obtain eight third cutting wheels having third wire grooves; S10, installing the eight third cutting wheels obtained in S09 in groups of four and arranged in a rectangular manner on the left and right cutting heads of the squarer to obtain two sets of third cutting wheel trains; S11, measuring the swing range of the tension wheel of the third cutting wheel system obtained in S10, making two third ring wires of a third circumference, and installing them in the third wire slots of the two sets of third cutting wheel systems respectively to form a third cutting mechanism to square the single crystal ingot; S12. After the third cutting wheel and the third annular wire have reached their service life, the third annular wire is discarded, the eight third cutting wheels are removed and the remaining annular coating layer is completely removed to retain the aluminum alloy substrate, and then S02 to S11 are repeated.
2. The method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism according to claim 1, characterized in that: The minimum distance in S01 is 8 mm.
3. The method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism according to claim 1, characterized in that: The material of the annular coating layer is polyurethane.
4. The method for reducing the maintenance cost of a single crystal ingot squaring mechanism according to claim 1, characterized in that: The outer radius of the aluminum alloy substrate is 125 mm; The vertical distance obtained in S01 is 133 mm; The outer radius of the annular coating layer is 130 mm and the inner radius is 118 mm; The annular coating layer has an annular width of 12 mm.
5. The method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism according to claim 1, characterized in that: The predetermined removal amount is 3 mm.
6. The method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism according to claim 1, characterized in that: The circumference of the first annular line is 3650 mm.
7. The method for reducing the maintenance cost of a single crystal ingot squaring and cutting mechanism according to claim 1, characterized in that: The circumference of the second annular line is 3630 mm.
8. The method for reducing the maintenance cost of a single crystal ingot squaring mechanism according to claim 1, characterized in that: The circumference of the third circular line is 3615 mm.