Floating grinding process method for surface deep processing of cement-based concrete imitation stone product

Abstract

The invention discloses a floating grinding process method for surface deep processing of a cement-based concrete imitation stone product. The floating grinding process method specifically comprises the following steps that 1, the height value of a product block is detected; 2, the central controller accumulates the height values of all the product blocks detected in the step 1, and the average value of the heights of the product blocks is obtained; and thirdly, the height error value of the product block is set to be + / -1 mm, the average value, obtained in the second step, of the height of the product block is input into a central controller, and the surface of the product block is ground with the pulse signal, passing through the grinding position inductive sensor, of the product block as the initial position, the feeding time and the feeding speed as variables and the pressure value F output by the air cylinder as grinding force. The invention solves the problems of high cost and damage to the decorative layer of the product in the existing fixed thickness treatment process.

Description

Technical Field

[0001] This invention belongs to the field of deep processing technology for the surface of cement-based concrete imitation stone products, and relates to a floating grinding process method for deep processing of the surface of cement-based concrete imitation stone products. Background Technology

[0002] Natural stone products are highly favored for their dense structure and natural texture, but their mining and processing cause significant environmental pollution. To meet environmental protection requirements, cement-based concrete imitation stone products have been developed as a new type of prefabricated building material. Existing cement-based concrete imitation stone products are made using a semi-dry hard concrete process to form imitation stone slabs and bricks. These products are composites of different materials for the surface layer and the base layer, resulting in a larger thickness deviation than the industry standard (the industry standard for qualified finished products has a thickness deviation of +2 or -1 mm (equivalent to a 3 mm dimensional deviation)). This makes it very inconvenient to further process the decorative surface layer of the products. The current conventional solution is to perform a fixed thickness treatment followed by grinding and polishing to achieve a surface texture similar to natural stone. However, the fixed thickness treatment process has the following problems: (i) Directly cutting the surface can easily cause "skin breakage" in products with decorative surface layer requirements, that is, the surface layer disappears and the base layer is exposed; (ii) Cutting the bottom surface first and then reversing to cut the surface increases equipment investment costs, and the back-and-forth flipping can easily cause chipped edges and corners. Summary of the Invention

[0003] The purpose of this invention is to provide a floating grinding process for deep processing of the surface of cement-based concrete imitation stone products, which solves the problems of high cost and damage to the decorative layer of the product caused by the existing fixed thickness processing process.

[0004] The technical solution adopted in this invention is a floating grinding process for deep processing of the surface of cement-based concrete imitation stone products, which specifically includes the following steps: Step 1: Detect the height of the product block; Step 2: The central controller sums up the height values ​​of all the workpiece blocks detected in Step 1 and calculates the average deviation of the workpiece block height. ; Step 3: Set the height error value of the product block, and use the average height h of the product block obtained in Step 2. j The input to the central controller is based on the pulse signal of the workpiece block passing through the grinding position sensor as the starting position, the feed time and feed speed as variables, and the pressure value F output by the cylinder as the grinding force to grind the surface of the workpiece block.

[0005] The invention is further characterized by: The specific process of step 1 is as follows: When the product blocks are sequentially conveyed by frequency conversion block-splitting conveyor A and frequency conversion block-splitting conveyor B to the position of the brick-splitting photoelectric sensor, the brick-splitting photoelectric sensor feeds back the product block's arrival signal to the central controller. After receiving the feedback signal, the central controller stops working on frequency conversion block-splitting conveyor A, while frequency conversion block-splitting conveyor B continues working until the brick-splitting photoelectric sensor detects the product block's disappearance signal and feeds back the disappearance signal to the central controller. At this point, the product blocks have been separated by the length of one product block. The central controller sends a start signal to frequency conversion block-splitting conveyor A, which starts and continues to transport product blocks to frequency conversion block-splitting conveyor B. The product blocks are then conveyed by frequency conversion block-splitting conveyor B to the frequency conversion grinding and polishing conveyor. When the product block is conveyed to the high-precision height detection sensor, the high-precision height detection sensor feeds back the measured product block height value to the central controller until the high-precision height detection sensor detects the disappearance signal of the product block.

[0006] The specific process of step 2 is as follows: Step 2.1: When the product block enters the variable frequency grinding and polishing conveyor, record and store the height h1 of the product block detected for the first time by the high-precision height detection sensor; Step 2.2: The workpiece continues to move, and the high-precision height detection sensor detects and records the height value of the workpiece once; respectively The data is fed back to the central controller and stored. Step 2.3: After the high-precision height detection sensor detects the disappearance of the signal from the workpiece block, the central controller sums up and averages the height values ​​of all workpiece blocks transmitted by the high-precision height detection sensor to obtain the average height of the workpiece blocks. ; (1) Where n is the number of times the height value of the product block is stored in the central controller.

[0007] The specific process of step 3 is as follows: when the central controller calculates the average deviation value of the product block height change... Then, using the pulse signal from the grinding position sensor as the starting position and the feed time as the variable, the time accumulator is started to record the running time t of the workpiece on the variable frequency grinding and polishing conveyor. By analyzing the relationship between the running distance of the workpiece and the position of the high-speed rotating suspended grinding head, the contact grinding area S of the high-speed rotating suspended grinding head during the running time t of the workpiece is obtained. i To maintain a constant pressure between the workpiece and the high-speed rotating suspended grinding head during the grinding process.

[0008] In step 3, the central controller refreshes the input gas pressure value of the cylinder in real time with the feed time and transmits it to the proportional gas pressure regulating valve. The grinding area changes in real time with the change of feed time, and the input gas pressure value p... iSynchronous updates ensure that the polishing pressure of each segment during the grinding process of the workpiece is strictly executed according to the process parameters pre-input into the central processing unit, thereby achieving stable pneumatic suspension control of the polishing pressure between the high-speed rotating suspension grinding head and the workpiece.

[0009] In step 3, the current of the speed-regulating motor driving the high-speed rotating suspended grinding head is detected in real time and fed back to the grinding head current feedback sensor. The load rate of the high-speed rotating suspended grinding head is fed back to the central controller, thus forming a closed-loop control.

[0010] In step 3, during the grinding process, the air source continuously provides sufficient compressed gas to the cylinder, ensuring that the cylinder can continuously exert its power to apply pressure.

[0011] In step 3, throughout the entire grinding process, The pressure p per unit area remains constant.

[0012] The beneficial effects of this invention are that, under the condition of decorative requirements and a thickness within the corresponding standard tolerance range of 3mm, this invention achieves a uniform and consistent decorative effect on the surface of cement-based concrete imitation stone products after grinding and polishing, through the selection of abrasive grit size in the cutter head assembly within the system. This allows for precise control of the material cutting amount on the decorative surface, achieving uniform surface thickness. Furthermore, due to the physical compression effect between the grinding disc and the product during cutting, a glass-like hardening effect is generated on the surface, further enhancing its strength and hardness. Servo-like cyclic control for individual products ensures that the thickness of the decorative surface material layer in batches tends to be uniform, reducing waste and improving production efficiency. The process method proposed in this invention allows for a variable cutting amount on the surface layer within a certain thickness and within a acceptable range (±1), ensuring that the thickness of the decorative surface layer after grinding is controllable within the design specifications and does not affect the strength of the decorative layer. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the floating grinding process for deep processing of cement-based concrete imitation stone products according to the present invention. Figure 2 This is a simplified diagram illustrating the process of a single product grinding disc moving and sweeping across the surface of a cement-based concrete imitation stone product in the floating grinding process of the present invention. Figure 3 This is a diagram showing the swept area between the grinding disc and the surface of the product in the floating grinding process for deep processing of cement-based concrete imitation stone products according to the present invention. Figure 4 This is a graph showing the pressure variation applied to the surface of cement-based concrete imitation stone products by a floating cylinder in the floating grinding process of the present invention.

[0014] In the diagram, 1. Brick-separation position detection photoelectric sensor, 2. Grinding position sensing sensor, 3. High-precision height detection sensor, 4. Grinding head current feedback sensor, 5. Proportional gas pressure regulating valve, 6. Central controller, 7. High-speed rotating suspended grinding head, 8. Cylinder, 9. Drive power source, 10. Air source, 11. Variable frequency block conveyor A, 12. Variable frequency block conveyor B, 13. Variable frequency grinding and polishing conveyor, 14. Product block. Detailed Implementation

[0015] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0016] Example 1 This invention relates to a floating grinding process for deep surface processing of cement-based concrete imitation stone products, such as... Figure 1 As shown, the specific steps include the following: Step 1, place the product block 14 on the frequency conversion block conveyor A11, and the product block 14 is conveyed to the frequency conversion block conveyor B12 through the frequency conversion block conveyor A11. Step 2: The variable frequency block conveyor B12 is equipped with a brick position detection photoelectric sensor 1. When it reaches the position of the brick position detection photoelectric sensor 1 (GD18 / GV18 (German Pepperl+Fuchs photoelectric sensor)), it detects the product block 14. The brick position detection photoelectric sensor 1 feeds back the position signal of the product block 14 to the central controller 6 (Modicon M258 French Schneider Modicon controller). After the central controller 6 receives the feedback signal, the variable frequency block conveyor A11 stops working. Step 3: The variable frequency block conveyor B12 continues to work until the brick-splitting position detection photoelectric sensor 1 detects the disappearance signal of the product block 14 and feeds back the disappearance signal to the central controller 6. At this time, the distance between the front and rear product blocks 14 has been increased by the length of one product block 14. Step 4: The central controller 6 sends a start signal to the frequency converter block conveyor A11, and the frequency converter block conveyor A11 starts and continues to transport the product block 14 to the frequency converter block conveyor B12. Step 5: The product block 14 is conveyed to the variable frequency grinding and polishing conveyor 13 via the variable frequency block conveyor B12. When the product block 14 is conveyed to the position of the high-precision (0.01mm) height detection sensor 3 (LWH-0050 (German NOVO position sensor)), the high-precision height detection sensor 3 measures the height information of the product block 14 every 10ms and feeds it back to the central controller 6 until the signal of the high-precision height detection sensor 3 detecting the product block 14 disappears. Step 6: The central controller 6 accumulates all height deviation values ​​of the product block 14 detected by the high-precision height detection sensor 3 (the high-precision height detection sensor 3 is pre-adjusted to the reference height h of the product block 14) and calculates the average deviation value (accuracy 0.1 mm). Step 7, combine the currently detected average deviation value h j Based on the calibration value in the pre-input central processing unit 6, namely the error height deviation value and the corresponding workpiece block 14 (the height error value of the workpiece block 14 is set to ±1mm) unit area pressure reference value p0, the input pressure value p of the cylinder 8 during the grinding process is automatically calculated after selection. i .

[0017] Example 2 The specific process of step 6 is as follows: Step 6.1: When the product block 14 enters the variable frequency grinding and polishing conveyor 13, record and store the height deviation value h1 of the product block 14 detected for the first time by the high-precision height detection sensor 3; Step 6.2: The product block 14 continues to move forward. Every 10ms, the high-precision height detection sensor 3 detects and records the height deviation value of the product block 14; respectively... The data is fed back to the central controller 6 and stored. Step 6.3: After the high-precision height detection sensor 3 detects the disappearance of the signal from the product block 14, the central controller 6 sums up and averages all the height deviation values ​​of the product block 14 transmitted by the high-precision height detection sensor 3 to obtain the average height deviation value of the product block 14. : (1) Where n is the number of height deviation values ​​of the product block 14 stored in the central controller 6.

[0018] Example 3 The specific process of step 7 is as follows: When the central controller 6 calculates the average deviation value h of the height change of product block 14 j Then, using the pulse signal from the grinding position sensor 2 (NBB8-18GM (Pepperl+Fuchs sensor)) as the starting position (pulse signal sent at 10ms intervals), and the feed time as a variable, the time accumulator is started to record the running time t of the workpiece block 14 on the variable frequency grinding and polishing conveyor 13. Since the conveying speed of the variable frequency grinding and polishing conveyor 13 is constant after the frequency conversion setting, ν*t = running distance. Through the running distance of the workpiece block 14 and the position relationship of the high-speed rotating suspended grinding head 7, the contact grinding area S of the high-speed rotating suspended grinding head 7 during the running time t of the workpiece block is calculated. i (cm) 2(Accurate to one decimal place); maintain a constant pressure between the workpiece 14 and the high-speed rotating suspended grinding head 7 during the grinding process. Let: the contact grinding area S i / piston area S at the force-applying end of cylinder 8 q Equal to air pressure conversion coefficient Then: the setpoint of the floating cylinder pressure control proportional valve 5. , (p i This represents the cylinder pressure corresponding to each time segment t. The central controller 6 refreshes the input gas pressure value of cylinder 8 in real time with the feed time at a period of 10ms, and transmits it to the proportional gas pressure regulating valve 5 (the proportional gas pressure regulating valve 5 is selected as an ITV105 Japanese SMC gas control valve, which controls the high-speed rotating suspended grinding head 7). The polishing area changes in real time with the change of feed time, and the input gas pressure value pi is updated synchronously. This ensures that the polishing pressure of each sub-unit (the grinding segment corresponding to the time period) during the grinding of the workpiece block 14 is strictly executed according to the process parameters (height deviation value, the pressure value of the workpiece block under the corresponding height deviation) in the pre-input central processor 6, thereby realizing the stable pneumatic suspension control of the polishing pressure between the high-speed rotating suspended grinding head 7 and the workpiece block 14. The current of the speed-regulating motor driving the high-speed rotating suspended grinding head 7 (grinding linear speed of 35m / s) is detected in real time and fed back to the grinding head current feedback sensor (AC current transmitter sensor) 4. This feedback of the high-speed rotating suspended grinding head 7's load rate (reflected in the motor's current value, primarily serving to protect the motor and prevent overload burnout due to mechanical jamming) is then sent to the central controller 6 (whose function is to monitor the grinding head load rate of the high-speed rotating suspended grinding head 7 to ensure it is below 100%, thus preventing the grinding head motor of the high-speed rotating suspended grinding head 7 from overloading), forming a closed-loop control system. During the grinding process, the air source 10 continuously provides sufficient compressed gas to the cylinder 8.

[0019] Example 4 The above control process is based on the first high-speed rotating floating grinding head 7, which is the first high-speed rotating floating grinding head 7 in the feed direction of the workpiece block 14. A grinding machine is composed of several high-speed rotating floating grinding heads 7 connected in series. The control method of each high-speed rotating floating grinding head 7 is the same as the control process of the first high-speed rotating floating grinding head 7 mentioned above. This process is repeated to form the floating grinding control system of the entire machine.

[0020] The basic mechanical principles throughout the grinding process Keeping the unit area pressure p (pressure on the product) constant, the force F on the product surface is directly proportional to the grinding area S; the larger the area S, the larger the force F, and vice versa. When the conveying speed is constant, the area is closely related to time. For ease of analysis, we divide the process into several specific time periods and use a diagram to simplify the relationship: see appendix. Figure 2 , Figure 3 , Figure 4 The relationship between the angle of the grinding disc of the high-speed rotating suspended grinding head 7 and the workpiece block 14 after contact with the workpiece block 14 and the time when the angle changes to the maximum center angle is shown in formula (2); the contact grinding area of ​​the high-speed rotating suspended grinding head 7 on the workpiece block 14 as time changes is calculated by formulas (3) to (9); then the dynamic pressure F of the bearing surface of the high-speed rotating suspended grinding head 7 on the workpiece block 14 can be obtained by calculating the dynamic cutting contact area S during cutting through the appropriate parameter pressure p.

[0021] Example 5 During grinding (the grinding disc of the high-speed rotating suspended grinding head 7 is fixed at its vertical axis, and the workpiece moves linearly from right to left according to the simplified diagram at a matching conveying speed ν), the sweeping area of ​​the cutting disc of the high-speed rotating suspended grinding head 7 on the surface of the workpiece is as follows: Figure 2 As shown, from left to right, the stages are divided into gradual, balanced, and gradually weakening phases: gradually increasing arc (O-O2: O-O2 is the segment where the contact area between the grinding head and the workpiece increases from zero to the largest fan-shaped area, i.e., Ⅰ→Ⅲ, where O1 and arc segment Ⅱ, α1, are only needed for the analysis at a certain moment in the process of Ⅰ→Ⅲ), arc + gradually increasing rectangle (O2-O3, i.e. Ⅲ→Ⅳ), arc + rectangle + gradually decreasing reverse arc (O3-O4, i.e. Ⅳ→Ⅴ), arc + rectangle The analysis employs five stages: a shape + an arc (O4-O5, i.e., V→VI, theoretically a constant), an arc + a rectangle + a gradually increasing reverse arc (O5-O6, i.e., VI→VII), and a gradually decreasing arc (O7-O9, i.e., VIII→X, where arcs O8 and IX are only necessary for analysis at a certain moment in the VIII→X process). (Note: The gradually decreasing reverse arc refers to the arc area formed by the cutter head and the edge of the workpiece gradually decreasing and disappearing as the workpiece moves, implying an increase in the sweeping area; conversely, the opposite is also true.) The continuous stepless change of the force applied by the cylinder is determined by simulating the area change.

[0022] Example 6 During grinding, the workpiece 14 has a length of L and a width of B, the grinding disc diameter of the high-speed rotating suspended grinding head 7 is Φ or 2R (and Φ>B), and the conveying speed v of the workpiece 14 is a constant value. After the workpiece 14 contacts (or leaves) the grinding disc, the central angle formed by the intersection of the circular grinding discs as they sweep across the workpiece surface varies with time t. α The central angle gradually increases or decreases alternately. Relationship with time t: (2) During grinding operations, the surface area swept by the grinding disc on a single workpiece per inspection time unit changes with time, and its area S(t): From O→O2 segment: (3) when Time: at this time Let C be a constant value; From O2 to O3: (4) From O3 to O4: (5) From O4 to O5: (6) From segment O5 to O6: (7) From segment O6 to O7: (8) From O7 to O9: (9) Through the operation of steps 1-7 above, the first high-speed rotating suspended grinding head 7 completes the grinding of a single product block 14. Each machine is equipped with multiple sets of grinding heads installed in series, and so on, repeating steps 1-7 for each grinding head, thereby achieving precise and controllable continuous grinding and polishing of multiple sets of high-speed rotating suspended grinding heads 7 installed in series. This invention uses online high-frequency real-time detection of the product height. The central processing unit averages the height error data and compares it with the pre-stored benchmark calibration value to generate the corresponding pressure parameters for the pressure cylinder on the grinding head. These parameters are then output to the cylinder via a proportional gas pressure regulating valve to complete the floating grinding of the product. This method uses micro-cutting processes such as grinding and polishing to obtain an ideal decorative surface layer effect, ensuring the effective strength of the decorative surface layer.

Claims

1. A floating grinding process for deep surface processing of cement-based concrete imitation stone products, characterized by: Specifically, the steps include the following: Step 1: Detect the height of the product block (14); Step 2: The central controller (6) sums up the height values ​​of all the product blocks (14) detected in Step 1 and calculates the average deviation of the height of the product blocks (14). ; Step 3, set the height error of the product block (14), and take the average height h of the product block (14) obtained in step 2. j The input to the central controller (6) is to use the pulse signal of the grinding position sensor (2) of the workpiece block (14) as the starting position, the feed time and feed speed as variables, and the pressure value F output by the cylinder (8) as the grinding force to grind the surface of the workpiece block (14).

2. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 1, characterized in that: The specific process of step 1 is as follows: When the product block (14) is successively conveyed by the frequency conversion block conveyor A (11) and the frequency conversion block conveyor B (12) to the position of the brick-separation position detection photoelectric sensor (1), the brick-separation position detection photoelectric sensor (1) feeds back the position signal of the product block (14) to the central controller (6). After receiving the feedback signal, the central controller (6) stops working on the frequency conversion block conveyor A (11) and continues working on the frequency conversion block conveyor B (12) until the brick-separation position detection photoelectric sensor (1) detects the disappearance signal of the product block (14) and feeds back the disappearance signal to the central controller (6). At this time, the product blocks (14) in front and behind have been separated. The length of a product block (14) is as follows: The central controller (6) sends a start signal to the frequency conversion block conveyor A (11), the frequency conversion block conveyor A (11) starts and continues to transport the product block (14) to the frequency conversion block conveyor B (12), and then through the frequency conversion block conveyor B (12) to the frequency conversion grinding and polishing conveyor (13). When the product block (14) is transported to the high-precision height detection sensor (3), the high-precision height detection sensor (3) feeds back the measured height value of the product block (14) to the central controller (6) until the signal of the high-precision height detection sensor (3) detects the product block (14) disappears.

3. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 2, characterized in that: The specific process of step 2 is as follows: Step 2.1: When the product block (14) enters the variable frequency grinding and polishing conveyor (13), record the height h1 of the product block (14) detected for the first time by the high-precision height detection sensor (3) and store it; Step 2.2, the product block (14) continues to move, and the high-precision height detection sensor (3) detects and records the height value of the product block (14) once; respectively The feedback is sent to the central controller (6) and stored; Step 2.3: After the high-precision height detection sensor (3) detects the disappearance of the signal from the product block (14), the central controller (6) accumulates and averages the height values ​​of all product blocks (14) transmitted by the high-precision height detection sensor (3) to obtain the average height of the product block (14). ; （1） Where n is the number of times the height value of the product block (14) is stored in the central controller (6).

4. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 3, characterized in that: The specific process of step 3 is as follows: when the central controller (6) calculates the average deviation value of the height change of the product block (14) Then, taking the pulse signal from the grinding position sensor (2) of the workpiece block (14) as the starting position of the calculation and the feed time as the variable, the time accumulator is started to record the running time t of the workpiece block (14) on the variable frequency grinding and polishing conveyor (13). Through the running distance of the workpiece block (14) and the position relationship of the high-speed rotating suspended grinding head (7), the contact grinding area S of the high-speed rotating suspended grinding head (7) during the running time t of the workpiece block is obtained. i The pressure between the workpiece block (14) and the high-speed rotating suspended grinding head (7) remains constant during the grinding process.

5. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 4, characterized in that: In step 3, the central controller (6) refreshes the input gas pressure value of the cylinder (8) in real time with the feed time and transmits it to the proportional gas pressure regulating valve (5). The grinding area changes in real time with the change of feed time, and the input gas pressure value p i Synchronous updates ensure that the polishing pressure of each sub-unit segment during the grinding process of the product block (14) is strictly executed according to the process parameters pre-input to the central processing unit (6), thereby achieving stable pneumatic suspension control of the polishing pressure between the high-speed rotating suspended grinding head (7) and the product block (14).

6. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 5, characterized in that: In step 3, the current of the speed-regulating motor of the driving power source (9) of the high-speed rotating suspended grinding head (7) is detected in real time and fed back to the grinding head current feedback sensor (4), and the load rate of the high-speed rotating suspended grinding head (7) is fed back to the central controller (6), thus forming a closed-loop control.

7. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 6, characterized in that: In step 3, during the grinding process, the air source (10) continuously provides sufficient compressed gas to the cylinder (8) to ensure that the cylinder (8) can continuously exert the power of applying pressure.

8. The floating grinding process for deep surface processing of cement-based concrete imitation stone products according to claim 8, characterized in that: In step 3, throughout the entire grinding process... Keep the pressure p per unit area constant.

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