Method for AI real-time monitoring of steel wire abrasion and automatic process optimization

Abstract

The invention relates to the technical field of silicon wafer cutting processing, in particular to a method for AI real-time monitoring of steel wire abrasion and automatic process optimization, which comprises the following steps: S1, a worker imports a primary edition cutting process to a slicing machine, sets a steel wire parameter protection value, and operates the machine to start cutting; s2, a visual camera module located at a pay-off wheel starts to monitor the emery exposure height and exposure rate of the new wire steel wire at the pay-off end, a numerical control unit collects data and calculates an average value, and the exposure rate and exposure height of each section of new wire are obtained; s3, a visual camera module located at a take-up wheel starts to monitor the emery exposure height and exposure rate of the old steel wire at the take-up end, a numerical control unit collects data and calculates an average value, and therefore the abrasion condition of the section of steel wire is obtained; s4, the numerical control unit compares the collected data with the parameter protection value, the slicing machine is driven by the controller to adjust the wire feeding period, and according to the technical scheme, the wire using amount is increased or reduced according to the abrasion condition of the steel wire, and the steel wire is reasonably utilized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of silicon wafer cutting processing, in particular to a method for AI real-time monitoring of steel wire wear and automatic process optimization. BACKGROUND

[0002] At present, in the silicon wafer cutting process in the field of solar energy, solar-grade cell silicon wafers are cut from silicon blocks or rods by a multi-wire cutting machine. According to the current development trend of the industry, steel wire mesh cutting technology will become the mainstream of cutting silicon wafers in the future. The existing steel wire cutting process is manually imported into the machine, and after starting the wafer cutting machine, the machine will completely cut according to the imported process until the end. The existing cutting process mode cannot monitor the wear of the steel wire in real time, and the excessively worn steel wire in some sections leads to abnormal cutting such as wire marks and broken wires. SUMMARY

[0003] In view of the above technical deficiencies, the purpose of the present application is to provide a method for AI real-time monitoring of steel wire wear and automatic process optimization. The required equipment includes a mounting bracket installed at the pay-off wheel and the take-up wheel of the wafer cutting machine, a fixed wire pulley and a movable wire pulley for guiding the steel wire are arranged on the mounting bracket, a visual camera module for monitoring the horizontal movement of the steel wire between the fixed wire pulley and the movable wire pulley is arranged on the mounting bracket, and a light supplementing module for lighting the steel wire is arranged on the mounting bracket, a numerical control unit for processing the detection data of the visual camera module is arranged on the mounting bracket, and the numerical control unit is connected to a rotary driver for driving the rotation of the pay-off wheel and the take-up wheel through a controller signal.

[0004] S1, the operator imports the initial cutting process to the wafer cutting machine, sets the steel wire parameter protection value, and runs the machine to start cutting;

[0005] S2, the visual camera module located at the pay-off wheel starts to monitor the diamond grit blade height and rate of the new wire steel wire at the pay-off end, the numerical control unit collects data, calculates the average value, and obtains the blade height and rate of each new wire;

[0006] S3, the visual camera module located at the take-up wheel starts to monitor the diamond grit blade height and rate of the old wire steel wire at the take-up end, the numerical control unit collects data, calculates the average value, and obtains the wear condition of the steel wire in this section;

[0007] S4, the numerical control unit compares the collected data with the parameter protection value, if the blade height and rate are greater than the preset protection value, it means that the steel wire is not seriously worn, the numerical control unit drives the wafer cutting machine to reduce the wire feeding period, so that the steel wire in this section can participate in the cutting process, and the rich cutting force is fully utilized, otherwise, the wire feeding period is increased and the wire take-up period is reduced.

[0008] In order to ensure that the visual camera module can clearly capture the details of the blade height and the blade rate of the steel wire diamond, the following features are specifically provided: the light supplement module includes two oppositely arranged lamp rings, the lamp rings are respectively mounted on the mounting plate, the mounting plate is provided with a through hole coaxial with the lamp ring, the steel wire guided by the fixed wire pulley and the moving wire pulley passes through the lamp ring and the through hole along the axis of the lamp ring, and the visual camera module is located between the two lamp rings.

[0009] In order to ensure that the visual camera module can comprehensively capture the state of the steel wire, the following features are specifically provided: the visual camera module includes a first high-speed visual camera, the detection end of the first high-speed visual camera is vertically downward, and the first high-speed visual camera is located directly above the steel wire guided by the fixed wire pulley and the moving wire pulley.

[0010] Preferably, the visual camera module further includes a second high-speed visual camera, the second high-speed visual camera is located on one side of the first high-speed visual camera, the visual camera module further includes a first reflector arranged below the first high-speed visual camera and a second reflector arranged below the second high-speed visual camera, the first reflector and the second reflector are oppositely inclined, and the first reflector and the second reflector reflect the image at the bottom of the steel wire to the second high-speed visual camera.

[0011] In order to ensure that the first reflector and the second reflector can reflect the situation at the bottom of the steel wire to the second high-speed visual camera in actual use scene, the following features are specifically provided: the first reflector and the second reflector are both mounted on the base, the bottom of the base is provided with a horizontal threaded shaft, the base is rotatably mounted on the support frame through the threaded shaft, the support frame is fixedly mounted on the mounting frame, and a locking nut for locking the inclination angle of the first reflector and the second reflector is spirally mounted on the threaded shaft.

[0012] In order to adjust the shooting height position of the first high-speed visual camera and the second high-speed visual camera according to the actual use scene to achieve the best shooting effect, the following features are specifically provided: the first high-speed visual camera and the second high-speed visual camera are both fixedly mounted on the mounting seat, the mounting seat is slidingly mounted on the vertical slide rail provided on the mounting frame, and the mounting seat is slidingly adjusted along the slide rail to adjust the shooting height of the first high-speed visual camera and the second high-speed visual camera.

[0013] A first threaded hole is provided on the mounting seat, the axis of the first threaded hole is perpendicular to the surface of the slide rail, and a first locking bolt for locking the position of the mounting seat on the slide rail is spirally mounted in the first threaded hole.

[0014] In order to ensure the tension of the steel wire during monitoring, the following features are specifically provided: the moving wire pulley is rotatably installed on the installation force arm, the top of the installation force arm is provided with a sleeve, the sleeve is slidably installed on a slide rod provided on the installation frame, and the slide rod extends in a horizontal direction perpendicular to the axis of the fixed wire pulley.

[0015] Preferably, a linear actuator is provided on the installation frame, the working end of the linear actuator is fixedly connected with the sleeve, and the working end of the linear actuator moves along the length direction of the slide rod.

[0016] Preferably, a second threaded hole is provided on the sleeve, the axis of the second threaded hole is perpendicular to the surface of the slide rod, and a second locking bolt for locking the position of the sleeve on the slide rod is spirally installed in the second threaded hole.

[0017] The beneficial effects of the present application compared with the prior art are:

[0018] Firstly, the present application monitors the wear condition of the steel wire in real time through the visual camera module, adjusts the moving speed of the steel wire of the slicing machine through the numerical control module, increases or reduces the amount of wire according to the wear condition of each section of the steel wire, fully and uniformly utilizes each section of the steel wire, and ensures the quality of the cut silicon wafer.

[0019] Secondly, the first high-speed visual camera in the present application directly shoots the upper part of the steel wire, and the second high-speed visual camera obtains the image of the bottom of the steel wire through the first and second mirrors, effectively eliminates the single camera visual angle blind area, realizes the all-around state capture of the steel wire, more completely obtains the diamond grit height and diamond grit rate information in all directions of the steel wire, provides more comprehensive data support for the numerical control unit, further improves the accuracy of the steel wire wear judgment, and ensures that the subsequent process optimization is more suitable for the actual state of the steel wire.

[0020] Thirdly, the two light rings of the light supplementing module in the present application emit light at the same time, supplement light from both sides of the steel wire to the part of the steel wire between the two light rings, provide sufficient and uniform light for the visual camera module to shoot the diamond grit height of the steel wire, effectively reduce the shadow of the diamond grit on the surface of the steel wire due to uneven light irradiation, and ensure that the visual camera module clearly captures the diamond grit height and diamond grit rate details of the steel wire. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0022] Figure 1Data graph obtained by the staff for the initial cutting process;

[0023] Figure 2 Data graph obtained by the staff for the initial cutting process;

[0024] Figure 3 Data graph obtained by the staff for the initial cutting process;

[0025] Figure 4 Data graph obtained by the staff for the initial cutting process;

[0026] Figure 5 Data graph obtained by the staff for the initial cutting process;

[0027] Figure 6 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0028] Figure 7 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0029] Figure 8 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 7 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0030] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 9 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0031] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 10 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0032] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 11 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 10 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0033] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 12 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0034] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 13 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0035] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 14 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 13 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0036] The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 15 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. Figure 13 The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene. The perspective view of the installation rack, the visual camera module box and the light supplementing module in the actual installation scene.

[0037] Explanation of reference signs: 1, mounting frame; 1a, fixed wire pulley; 1b, movable wire pulley; 1b1, mounting force arm; 1b2, sleeve; 1b3, second threaded hole; 1b4, second locking bolt; 1c, numerical control unit; 1d, sliding rail; 1e, sliding rod; 1f, linear driver; 2, visual camera module; 2a, first high-speed visual camera; 2b, second high-speed visual camera; 2c, first reflector; 2c1, base; 2c2, threaded shaft; 2c3, support frame; 2c4, locking nut; 2d, second reflector; 2e, mounting seat; 2e1, first threaded hole; 2e2, first locking bolt; 3, light supplementing module; 3a, lamp ring; 3b, mounting plate; 3b1, through hole. DETAILED DESCRIPTION

[0038] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0039] Reference Figures 1 to 15 :

[0040] An AI real-time monitoring steel wire wear and automatic process optimization method, comprising a mounting frame 1 installed at a pay-off wheel and a take-up wheel of a slicing machine, a fixed wire pulley 1a and a movable wire pulley 1b for guiding the steel wire are arranged on the mounting frame 1, a visual camera module 2 for monitoring the horizontal movement of the steel wire between the fixed wire pulley 1a and the movable wire pulley 1b is arranged on the mounting frame 1, and a light supplementing module 3 for lighting the steel wire is arranged on the mounting frame 1, a numerical control unit 1c for processing the detection data of the visual camera module 2 is arranged on the mounting frame 1, and the numerical control unit 1c is connected to a rotary driver for driving the rotation of the pay-off wheel and the take-up wheel through a controller signal;

[0041] S1, the worker imports the initial cutting process to the slicing machine, sets the steel wire parameter protection value, and runs the machine to start cutting;

[0042] S2, the visual camera module 2 located at the pay-off wheel starts to monitor the new wire steel wire diamond blade height and blade rate, the numerical control unit 1c collects data, calculates the average value, and obtains the blade rate and blade height of each new wire;

[0043] S3, the visual camera module 2 located at the take-up wheel starts to monitor the old wire steel wire diamond blade height and blade rate, the numerical control unit 1c collects data, calculates the average value, and obtains the wear condition of the steel wire;

[0044] S4, the numerical control unit 1c compares the collected data with the parameter protection value, if the blade height and the blade rate are both greater than the preset protection value, it indicates that the steel wire is not seriously worn, the numerical control unit 1c drives the slicing machine through the controller to reduce the wire feeding period, so that the steel wire in this section can participate in the cutting process, and the excess cutting force is fully utilized, otherwise, the wire feeding period is increased and the wire winding period is reduced.

[0045] The embodiment is mainly applied to the slicing process, compared with the traditional slicing, the wear condition of the steel wire is monitored in real time, the cutting process is optimized according to the wear condition of each section of steel wire, so that each section of steel wire is fully and reasonably utilized, the blade rate of the embodiment is the number of diamond particles in the unit length of diamond wire, the blade height of the embodiment is the height of the diamond grit exposed outside the plating layer, and the cutting period of the embodiment is the length of the one-time wire feeding distance plus the one-time wire winding distance in the single step of the cutting process. The embodiment has good application effect in actual application, can ensure that each section of steel wire is fully and evenly utilized in the cutting process, reduces the abnormal rate of the cutting process, and improves the slicing yield. In actual application, taking tungsten wire 22 wire cutting of 187 size silicon wafer as an example, the staff imports the initial cutting process, and the data as shown in the table is obtained. Figure 1

[0046] Then, the steel wire monitoring parameter protection value is set, the new wire parameter is that the blade height is greater than 3.3 and the blade rate is greater than 95, the old wire parameter is that different parameter protection values are set according to steps, and the parameter protection values are as follows:

[0047] Step 1-step 5: the blade height is 3.1-3.3, and the blade rate is 90-95;

[0048] Step 5-step 8: the blade height is 2.9-3.1, and the blade rate is 85-90;

[0049] Step 8-step 11: the blade height is 2.7-2.9, and the blade rate is 70-85;

[0050] Step 11-step 16: the blade height is 2.5-2.7, and the blade rate is 65-70;

[0051] Step 16-step 18: the blade height is 2.3-2.5, and the blade rate is 50-65;

[0052] Step 18-step 21: the blade height is 2.0-2.3, and the blade rate is 40-50;

[0053] Then, the equipment is started and begins to run, the visual camera module 2 at the wire feeding wheel and the wire winding wheel begins to take pictures, and the data as shown in the table is obtained; 10 pictures are taken in a cycle of collecting new wire and old wire steel wire parameters, the numerical control unit 1c automatically analyzes the data to obtain the average value, and the specific data is as follows: Figure 2 Figure 3 ​​As shown.

[0054] After the numerical control unit 1c obtains the new line and the old line steel wire parameters, it is automatically compared whether it meets the parameter protection value. If the new line and the old line both meet the parameter protection value requirement, it continues to cut according to the initial version process. If the new line meets the parameter protection value and the old line is less than the parameter protection value, the numerical control unit 1c controls the slicing machine to enlarge the Step wire feeding period and reduce the wire return period, as shown in Figure 4 If the new line meets the parameter protection value and the old line is greater than the parameter protection value, the AI automatically reduces the Step wire feeding period and increases the wire collection period, as shown in Figure 5

[0055] In order to ensure that the visual camera module 2 can clearly capture the details of the steel wire diamond blade height and blade rate, the following features are specifically set:

[0056] The light supplement module 3 includes two oppositely arranged lamp rings 3a, which are respectively installed on the mounting plate 3b. The mounting plate 3b is provided with a through hole 3b1 coaxial with the lamp ring 3a. The steel wire guided by the fixed wire pulley 1a and the moving wire pulley 1b passes through the lamp ring 3a and the through hole 3b1 along the axis of the lamp ring 3a. The visual camera module 2 is located between the two lamp rings 3a.

[0057] Referring to Figures 11 to 13 In the embodiment, the two lamp rings 3a of the light supplement module 3 are oppositely arranged and respectively installed on the mounting plate 3b. The through hole 3b1 of the mounting plate 3b is coaxial with the lamp ring 3a, so that the steel wire guided by the fixed wire pulley 1a and the moving wire pulley 1b can pass through the lamp ring 3a and the through hole 3b1 along the axis of the lamp ring 3a. When the visual camera module 2 monitors the steel wire, the two lamp rings 3a emit light at the same time, supplementing light from both sides of the steel wire to the part of the steel wire located between the two lamp rings 3a, providing sufficient and uniform light for the visual camera module 2 to shoot the diamond blade state of the steel wire. Effectively reduce the shadow of the diamond on the surface of the steel wire due to uneven light irradiation, ensure that the visual camera module 2 can clearly capture the details of the steel wire diamond blade height and blade rate, and improve the accuracy of the data collected by the numerical control unit 1c.

[0058] In order to ensure that the visual camera module 2 can comprehensively capture the state of the steel wire, the following features are specifically set:

[0059] The visual camera module 2 includes a first high-speed visual camera 2a. The detection end of the first high-speed visual camera 2a is vertically downward. The first high-speed visual camera 2a is located directly above the steel wire guided by the fixed wire pulley 1a and the moving wire pulley 1b.

[0060] ​The visual camera module 2 further comprises a second high-speed visual camera 2b located on one side of the first high-speed visual camera 2a, and further comprises a first reflector 2c arranged below the first high-speed visual camera 2a and a second reflector 2d arranged below the second high-speed visual camera 2b, the first reflector 2c and the second reflector 2d are oppositely inclined, and the first reflector 2c and the second reflector 2d reflect the image of the bottom of the steel wire to the second high-speed visual camera 2b.

[0061] Reference Figures 7 to 11 In the embodiment, the detection end of the first high-speed visual camera 2a is vertically downward and located directly above the steel wire, and can directly capture the state of the upper part of the steel wire; the second high-speed visual camera 2b is located on one side of the first high-speed visual camera 2a, and the second reflector 2d below the second high-speed visual camera 2b is oppositely inclined with the first reflector 2c below the first high-speed visual camera 2a, the image of the bottom of the steel wire is reflected to the second reflector 2d through the first reflector 2c, and then reflected to the second high-speed visual camera 2b through the second reflector 2d, so that the second high-speed visual camera 2b can capture the state of the lower part of the steel wire. Through the cooperation of the two, the image of the steel wire in multiple directions around the steel wire is collected. In the embodiment, the first high-speed visual camera 2a directly photographs the upper part of the steel wire, and the second high-speed visual camera 2b obtains the image of the bottom of the steel wire through the first reflector 2c and the second reflector 2d, which effectively eliminates the visual angle blind area of a single camera and realizes the full-state capture of the steel wire around the steel wire; the grit protrusion height and protrusion rate information of the steel wire in each direction can be more completely obtained, which provides more comprehensive data support for the numerical control unit 1c, further improves the accuracy of the steel wire wear judgment, and ensures that the subsequent process optimization is more in line with the actual state of the steel wire.

[0062] In order to ensure that the first reflector 2c and the second reflector 2d can reflect the situation of the bottom of the steel wire to the second high-speed visual camera 2b in actual use scenarios, the following features are specifically provided:

[0063] The first reflector 2c and the second reflector 2d are both mounted on the base 2c1, the base 2c1 is provided with a horizontal threaded shaft 2c2 at the bottom, the base 2c1 is rotatably mounted on the support frame 2c3 through the threaded shaft 2c2, the support frame 2c3 is fixedly mounted on the mounting frame 1, and the threaded shaft 2c2 is spirally provided with a locking nut 2c4 for locking the inclination angle of the first reflector 2c and the second reflector 2d.

[0064] Reference Figure 11 and Figure 15In actual use, the worker can loosen the locking nut 2c4, rotate the threaded shaft 2c2 to drive the base 2c1 to rotate, thereby adjusting the inclination angles of the first reflector 2c and the second reflector 2d, until the image at the bottom of the steel wire can be clearly transmitted to the second high-speed vision camera 2b after being reflected by the double mirrors; after the angle adjustment is completed, the locking nut 2c4 is tightened to lock the threaded shaft 2c2, and the angles of the reflectors are fixed. In this embodiment, the threaded shaft 2c2 and the locking nut 2c4 are matched to realize flexible adjustment and stable locking of the inclination angles of the first reflector 2c and the second reflector 2d, which can adapt to actual scene variables such as different steel wire positions, camera installation errors, etc., ensure the accuracy of the reflection path, and ensure that the second high-speed vision camera 2b can stably capture the state of the bottom of the steel wire.

[0065] In order to adjust the shooting height positions of the first high-speed vision camera 2a and the second high-speed vision camera 2b according to actual use scenarios to achieve the best shooting effect, the following features are specifically provided:

[0066] The first high-speed vision camera 2a and the second high-speed vision camera 2b are both fixedly installed on the mounting seat 2e, and the mounting seat 2e is slidingly installed on the vertical slide rail 1d provided on the mounting frame 1. The mounting seat 2e slides along the slide rail 1d to adjust the shooting height of the first high-speed vision camera 2a and the second high-speed vision camera 2b.

[0067] The mounting seat 2e is provided with a first threaded hole 2e1, and the axis of the first threaded hole 2e1 is perpendicular to the surface of the slide rail 1d. A first locking bolt 2e2 for locking the position of the mounting seat 2e on the slide rail 1d is spirally installed in the first threaded hole 2e1.

[0068] Reference Figures 8 to 13 In this embodiment, the first high-speed vision camera 2a and the second high-speed vision camera 2b are both fixed on the mounting seat 2e. When adjusting the shooting height, the first locking bolt 2e2 in the first threaded hole 2e1 on the mounting seat 2e is loosened, so that the mounting seat 2e can slide up and down along the slide rail 1d until the camera is at the optimal shooting height. After adjustment, the first locking bolt 2e2 is tightened so that the end thereof tightly presses the surface of the slide rail 1d, thereby locking the position of the mounting seat 2e and the camera. In this embodiment, the shooting height of the first high-speed vision camera 2a and the second high-speed vision camera 2b can be flexibly adjusted to adapt to actual scene requirements such as changes in the position of the steel wire and changes in the focal length of the lens, so that the camera is always at the optimal shooting height, and the clarity and detail capture capability of the steel wire state image are improved.

[0069] In order to ensure the tension of the steel wire during monitoring, the following features are specifically provided:

[0070] The mobile guide wire pulley 1b is rotatably installed on the installation force arm 1b1, and a sleeve 1b2 is arranged at the top of the installation force arm 1b1. The sleeve 1b2 is slidably installed on a sliding rod 1e arranged on the installation frame 1, and the sliding rod 1e extends in a horizontal direction perpendicular to the axis of the fixed guide wire pulley 1a.

[0071] A linear actuator 1f is arranged on the installation frame 1, and the working end of the linear actuator 1f is fixedly connected with the sleeve 1b2. The working end of the linear actuator 1f moves along the length direction of the sliding rod 1e.

[0072] A second threaded hole 1b3 is arranged on the sleeve 1b2, and the axis of the second threaded hole 1b3 is perpendicular to the surface of the sliding rod 1e. A second locking bolt 1b4 for locking the position of the sleeve 1b2 on the sliding rod 1e is spirally installed in the second threaded hole 1b3.

[0073] With reference to Figures 12 to 14 , the linear actuator 1f in the embodiment can be a pneumatic cylinder, an oil cylinder or an electric push rod, etc. The working end of the linear actuator 1f pushes or pulls the sleeve 1b2 along the length direction of the sliding rod 1e, drives the installation force arm 1b1 and the mobile guide wire pulley 1b to move horizontally, changes the distance between the mobile guide wire pulley 1b and the fixed guide wire pulley 1a, and adjusts the tension of the steel wire. After the tension reaches the preset value, the second locking bolt 1b4 is tightened, the end of the second locking bolt 1b4 abuts against the surface of the sliding rod 1e, the position of the sleeve 1b2 is locked to keep the tension stable, the steel wire is kept in a stable tension state during monitoring through accurate control of the tension of the steel wire, the steel wire is prevented from shaking due to over-loose or over-tight tension, and the clarity and stability of the image captured by the visual camera module 2 are ensured.

[0074] Working principle: The worker imports the initial cutting process into the slicing machine, sets the steel wire parameter protection value, and runs the machine to start cutting. The visual camera module 2 located at the pay-off reel starts to monitor the new wire steel wire diamond blade height and blade rate at the pay-off end, the numerical control unit 1c collects data, calculates the average value, and obtains the blade height and blade rate of each new wire. The visual camera module 2 located at the take-up reel starts to monitor the old wire steel wire diamond blade height and blade rate at the take-up end, the numerical control unit 1c collects data, calculates the average value, and obtains the wear condition of the steel wire. The numerical control unit 1c compares the collected data with the parameter protection value. If the blade height and the blade rate are both greater than the preset protection value, it indicates that the steel wire is not seriously worn, the numerical control unit 1c drives the slicing machine through the controller to reduce the wire feeding period, so that the steel wire increases the participation in the cutting process, and the rich cutting force is fully utilized. Otherwise, the wire feeding period is increased and the wire take-up period is reduced.

[0075] Obviously, many modifications and variations of the present application are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims and their equivalents, the application can be practiced otherwise than as specifically described.

Claims

1. A method for real-time monitoring of steel wire wear and automatic process optimization using AI, characterized in that: The invention comprises a mounting frame (1) mounted at the pay-off wheel and the take-up wheel of a slicer, wherein a fixed wire pulley (1a) and a movable wire pulley (1b) for guiding the steel wire are provided on the mounting frame (1), a visual camera module (2) for monitoring the steel wire moving horizontally between the fixed wire pulley (1a) and the movable wire pulley (1b), and a fill light module (3) for lighting the steel wire are provided on the mounting frame (1), and a numerical control unit (1c) for processing detection data of the visual camera module (2) is provided on the mounting frame (1), and the numerical control unit (1c) is connected to a rotary driver for driving the pay-off wheel and the take-up wheel to rotate via a controller signal; S1. The staff imports the initial cutting process into the slicer, sets the steel wire parameter protection value, and runs the machine to start cutting; S2, the visual camera module (2) located at the pay-off wheel starts to monitor the diamond cutting edge height and cutting edge rate of the steel wire at the pay-off end (new wire), and the numerical control unit (1c) collects the data, calculates the average value, and obtains the cutting edge rate and cutting edge height of each new wire segment; S3, the visual camera module (2) located at the take-up wheel starts to monitor the diamond cutting edge height and cutting edge rate of the steel wire at the take-up end (old wire), and the numerical control unit (1c) collects the data and calculates the average value to obtain the wear condition of the steel wire section; S4. The numerical control unit (1c) compares the collected data with the parameter protection value. If the blade height and the blade rate are both greater than the preset protection value, it means that the steel wire is not seriously worn. The numerical control unit (1c) drives the slicer through the controller to reduce the wire feeding cycle, so that the section of steel wire can participate more in the cutting process and fully utilize the surplus cutting force. Otherwise, the wire feeding cycle is increased and the wire taking-up cycle is reduced.

2. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 1 is characterized in that: The fill light module (3) comprises two light rings (3a) arranged opposite to each other, the light rings (3a) being respectively mounted on a mounting plate (3b), the mounting plate (3b) being provided with a through hole (3b1) coaxial with the light ring (3a), a steel wire guided by a fixed wire pulley (1a) and a movable wire pulley (1b) passing through the light ring (3a) and the through hole (3b1) along the axis of the light ring (3a), and the visual camera module (2) being located between the two light rings (3a).

3. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 2, characterized in that: The visual camera module (2) comprises a first high-speed visual camera (2a), the detection end of the first high-speed visual camera (2a) is arranged vertically downward, and the first high-speed visual camera (2a) is located directly above the steel wire guided by the fixed wire pulley (1a) and the movable wire pulley (1b).

4. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 3 is characterized in that: The visual camera module (2) further includes a second high-speed visual camera (2b), which is located on one side of the first high-speed visual camera (2a). The visual camera module (2) further includes a first reflector (2c) arranged below the first high-speed visual camera (2a) and a second reflector (2d) arranged below the second high-speed visual camera (2b). The first reflector (2c) and the second reflector (2d) are arranged to be relatively inclined. The first reflector (2c) and the second reflector (2d) reflect the image of the bottom of the steel wire to the second high-speed visual camera (2b).

5. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 4 is characterized in that: The first reflector (2c) and the second reflector (2d) are both mounted on a base (2c1); a horizontal threaded shaft (2c2) is provided at the bottom of the base (2c1); the base (2c1) is rotatably mounted on a support frame (2c3) via the threaded shaft (2c2); the support frame (2c3) is fixedly mounted on the mounting frame (1); a locking nut (2c4) for locking the tilt angle of the first reflector (2c) and the second reflector (2d) is screwed onto the threaded shaft (2c2).

6. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 4 is characterized in that: The first high-speed vision camera (2a) and the second high-speed vision camera (2b) are both fixedly mounted on a mounting base (2e), and the mounting base (2e) is slidably mounted on a vertical slide rail (1d) provided on the mounting frame (1), and the mounting base (2e) slides along the slide rail (1d) to adjust the shooting height of the first high-speed vision camera (2a) and the second high-speed vision camera (2b).

7. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 6, characterized in that: A first threaded hole (2e1) is provided on the mounting seat (2e), the axis of the first threaded hole (2e1) is perpendicular to the surface of the slide rail (1d), and a first locking bolt (2e2) is screwedly installed in the first threaded hole (2e1) for locking the position of the mounting seat (2e) on the slide rail (1d).

8. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 1, characterized in that: The movable wire pulley (1b) is rotatably mounted on the mounting arm (1b1), a sleeve (1b2) is provided on the top of the mounting arm (1b1), the sleeve (1b2) is slidably mounted on a slide rod (1e) provided on the mounting frame (1), and the slide rod (1e) extends in a horizontal direction perpendicular to the axis of the fixed wire pulley (1a).

9. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 8, characterized in that: A linear drive (1f) is provided on the mounting frame (1), a working end of the linear drive (1f) is fixedly connected to the sleeve (1b2), and the working end of the linear drive (1f) moves along the length direction of the slide rod (1e).

10. The method of AI real-time monitoring of steel wire wear and automatic process optimization according to claim 9, characterized in that: A second threaded hole (1b3) is provided on the sleeve (1b2), the axis of the second threaded hole (1b3) is perpendicular to the surface of the slide rod (1e), and a second locking bolt (1b4) for locking the position of the sleeve (1b2) on the slide rod (1e) is screwed into the second threaded hole (1b3).

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