Water gap shearing method, device and equipment based on water gap shearing machine and medium

Abstract

The invention provides a water gap shearing method based on a water gap shearing machine. The water gap shearing method comprises the steps that a control module executes initialization operation, and the working pressure and shearing time sequence parameters of pneumatic scissors are set; the pneumatic driving unit enters a preset automatic working cycle according to the starting instruction, outputs a shearing signal, and continuously outputs a first driving signal of a first preset time to the pneumatic driving unit according to a shearing time sequence parameter, so that the compressed air adjusted by the pressure adjusting and flow stabilizing unit drives pneumatic scissors to execute shearing operation; when the first preset time is over, the control module cuts off the first driving signal, and the pneumatic driving unit closes the pneumatic scissors to reset; the control module enters an interval waiting period; and after the second preset time is over, a shearing signal is output, and shearing circulation of the water gap of the next station is started until shearing of the preset water gap is completed. According to the technical scheme of the embodiment, the water gap shearing machine can automatically shear water gaps of products, and the water gap shearing efficiency of the products is improved.

Description

Technical Field

[0001] This invention relates to the field of sprue cutting machine technology, and particularly to a sprue cutting method, apparatus, equipment and medium based on a sprue cutting machine. Background Technology

[0002] In the plastic injection molding industry, products often have excess sprues and gates attached after demolding; these parts are collectively referred to as "sprues." The presence of sprues not only affects the appearance of the product but may also cause interference in subsequent assembly or electroplating processes, therefore they must be removed.

[0003] However, in existing technologies, the removal of sprues from plastic products typically involves operators using manual scissors or clamps, relying on experience to identify and cut the sprues. This method has significant drawbacks: First, it is inefficient, highly dependent on the operator's skill level, and has become a bottleneck process on automated production lines. Second, product quality is inconsistent; the cutting force, angle, and position vary from person to person, easily leading to uneven cutting, stress whitening, or even damage, resulting in a high product scrap rate. Furthermore, long-term repetitive labor can easily lead to operator fatigue and occupational health problems. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, the present invention proposes a sprue-cutting method, apparatus, equipment, and medium based on a sprue-cutting machine, which enables the sprue-cutting machine to automatically sprue products and improve the efficiency of product sprue-cutting.

[0005] In a first aspect, embodiments of the present invention provide a method for cutting sprues based on a sprue cutter, applied in a fully automatic sprue cutter. The fully automatic sprue cutter includes a control module, a pneumatic drive unit, a pressure regulating and flow stabilizing unit, and pneumatic shears. The control module is connected to the pneumatic drive unit, the pressure regulating and flow stabilizing unit, and the pneumatic shears, respectively. The method includes: The control module performs an initialization operation, sets the working pressure of the pneumatic shears through the pressure regulating and flow stabilizing unit, and sets the shearing timing parameters in the control module; The control module enters a preset automatic working cycle according to the start command and outputs a shearing signal. The control module continuously outputs a first drive signal for a first preset time to the pneumatic drive unit according to the shearing timing parameters. The pneumatic drive unit responds to the first drive signal to drive the pneumatic shears with compressed air regulated by the pressure regulating and flow stabilizing unit to perform shearing operations on the sprue of the workpiece. When the first preset time ends, the control module cuts off the first drive signal, the pneumatic drive unit shuts down, and the pneumatic scissors reset to the ready state; The control module enters a second preset time interval waiting period; After the second preset time ends, the shearing signal is output again to start the shearing cycle for the next station nozzle until all preset nozzles are sheared or a stop signal is received.

[0006] In some embodiments of the present invention, the pneumatic drive unit is provided with a solenoid valve, and the pneumatic drive unit responds to the first drive signal, including: The solenoid valve is activated in response to the first drive signal to establish the flow path of the compressed air; Compressed air is delivered to the cylinder of the pneumatic scissors at a set stable working pressure; The piston rod of the cylinder moves under air pressure and drives the blade of the pneumatic scissors to close, thus completing the shearing process.

[0007] In some embodiments of the present invention, the control module continuously outputs a first drive signal for a first preset time to the pneumatic drive unit according to the shearing timing parameters, including: The first drive signal is set to a first duration to ensure that the pneumatic shears complete a single cutting and resetting action. The first drive signal is set to a second duration so that the workpiece can move and be positioned between the sprue stations. The control module enters a preset automatic working cycle according to the start command.

[0008] In some embodiments of the present invention, the control module is further provided with a time relay, and the control module enters a preset automatic working cycle according to a start command, including: When the internal timing duration of the time relay is the same as the first duration, the first drive signal is automatically cut off; The pneumatic scissors shut down when the power is off, cutting off the flow path of the compressed air, expelling the gas inside the pneumatic scissors, and causing the blades of the pneumatic scissors to open. The automatic work cycle stops when all the preset nozzles have completed shearing.

[0009] In some embodiments of the present invention, the control module is further provided with a cycle counter, wherein stopping the automatic working cycle when all the preset water inlets have completed shearing includes: The cycle counter is reset, and when the preset water inlet is cyclically sheared, the cycle counter is incremented once; The current value of the cycle counter is compared with a preset threshold for the total number of water inlets; When the current value of the cycle counter is greater than or equal to the threshold value of the total number of water inlets, the automatic working cycle stops.

[0010] In some embodiments of the present invention, before the control module enters a preset automatic working cycle according to the start command, the method further includes: The current pressure value of the compressed air is collected in real time, and the current pressure value is compared with the minimum working pressure threshold of the pneumatic scissors. When the current pressure value is greater than or equal to the minimum working pressure threshold, the current pressure value is determined to be valid, and the control module sends the first drive signal to the pneumatic shears. When the current pressure value is lower than the minimum working pressure threshold, the control module generates an insufficient air pressure alarm signal and locks the air pressure drive unit.

[0011] In some embodiments of the present invention, driving the pneumatic shears with compressed air regulated by the pressure regulating and flow stabilizing unit includes: The current air pressure value of the compressed air flowing through the pressure regulating and flow stabilizing unit is collected in real time, wherein the current air pressure value is the instantaneous pressure data of the compressed air at the output end of the pressure regulating and flow stabilizing unit; When the current air pressure value is lower than the preset air pressure threshold, and the difference between the current air pressure value and the air pressure threshold is less than the first pressure difference range, the pressure regulating and flow stabilizing unit performs a step-by-step pressurization operation on the compressed air until the current air pressure value reaches the second pressure difference range of the air pressure threshold, at which point the pressure regulating and flow stabilizing unit stops operating. When the current air pressure value is higher than the air pressure threshold and the difference is greater than the first pressure difference range, the pressure regulating and flow stabilizing unit performs a graded pressure reduction operation on the compressed air and simultaneously feeds back the reduced air pressure data to the control module in real time until the current air pressure value stabilizes within the second pressure difference range of the air pressure threshold, at which point the pressure regulating and flow stabilizing unit stops operating.

[0012] In a second aspect, embodiments of the present invention provide a sprue-cutting device based on a sprue-cutting machine, including at least one control processor and a memory for communicatively connecting to the at least one control processor; the memory stores instructions executable by the at least one control processor, which, when executed by the at least one control processor, enables the at least one control processor to perform the sprue-cutting method based on the sprue-cutting machine as described in the first aspect above.

[0013] Thirdly, embodiments of the present invention provide an electronic device including a sprue-cutting device based on a sprue-cutting machine as described in the second aspect above.

[0014] Fourthly, embodiments of the present invention provide a computer-readable storage medium storing computer-executable instructions for performing the sprue-cutting method based on a sprue-cutting machine as described in the first aspect above.

[0015] The sprue-cutting method based on a sprue-cutting machine according to embodiments of the present invention has at least the following beneficial effects: After initialization via the control module (setting working pressure and shearing timing parameters), automatic cycling can be triggered by a start command. Operators do not need complex equipment debugging or manual operation skills, reducing personnel training costs and lowering the operational threshold. Simultaneously, the shearing timing parameters (first preset time, second preset time) can be flexibly adjusted according to workpiece type and sprue specifications, adapting to the production needs of different products without significant modifications to the equipment structure, thus improving process flexibility. Furthermore, fully automated operation reduces direct contact between operators and pneumatic shears (high-speed moving parts), avoiding the risk of mechanical injury that may occur during manual operation and improving production safety. Attached Figure Description

[0016] Figure 1 This is a flowchart of a sprue cutting method based on a sprue cutting machine provided in one embodiment of the present invention; Figure 2 This is a flowchart of the pneumatic drive unit responding to the first drive signal according to an embodiment of the present invention; Figure 3 This is a flowchart of the control module outputting a first drive signal to the pneumatic drive unit according to an embodiment of the present invention; Figure 4 This is a flowchart of the control module entering a preset automatic working cycle according to the start command provided in the embodiment of the present invention; Figure 5 This is a flowchart provided by an embodiment of the present invention, showing the automatic working cycle stopping when all preset water inlets have completed shearing; Figure 6 This is a flowchart provided in an embodiment of the present invention before entering a preset automatic work cycle according to a start command; Figure 7 This is a flowchart of compressed air driving pneumatic shears after being regulated by a pressure regulating and flow stabilizing unit, provided in an embodiment of the present invention; Figure 8 This is a structural diagram of a sprue-cutting device based on a sprue-cutting machine provided in another embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of a fully automatic sprue cutter provided in one embodiment of the present invention; Figure 10This is a schematic diagram of the principle of a fully automatic sprue cutter provided in one embodiment of the present invention. Detailed Implementation

[0017] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0018] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0019] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0020] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0021] Reference Figure 9 and Figure 10 This invention provides a fully automatic sprue cutter, including a control module 100, a pneumatic drive unit 200, a pressure regulating and flow stabilizing unit 300, and a pneumatic shear 400. The control module 100 is connected to the pneumatic drive unit 200, the pressure regulating and flow stabilizing unit 300, and the pneumatic shear 400. The pneumatic drive unit 200 is equipped with a solenoid valve, and the control module 100 is also equipped with a time relay 110 and a cycle counter 120.

[0022] It should be noted that the control module 100 receives core parameters set by the operator for the pneumatic shears 400, such as working pressure, shearing timing parameters (first duration, second duration), and total number of nozzles threshold, and sends the first drive signal to the pressure regulating and flow stabilizing unit 300; receives start / stop signals and outputs the first drive signal to the pneumatic drive unit 200 (solenoid valve) according to preset logic to control the start of the shearing action; at the same time, it coordinates the timing of each module to ensure that the shearing, reset, waiting, and next shearing cycle proceed in an orderly manner; it receives real-time air pressure data fed back by the pressure regulating and flow stabilizing unit 300, timing data from the time relay 110, and counting data from the cycle counter 120, and performs logical judgments (such as whether the air pressure meets the standard and whether the shearing count is completed); when the air pressure is detected to be lower than the minimum working pressure threshold, an alarm signal is generated and the pneumatic drive unit 200 is locked; when the cycle counter 120 reaches the total number of nozzles threshold, the working cycle is automatically stopped to ensure system safety and operational integrity.

[0023] The pneumatic drive unit 200 is used to receive the first drive signal output by the control module 100, control the solenoid valve to start / close, and then establish / cut off the flow path of compressed air to realize the start and stop of the pneumatic scissors 400. After the solenoid valve is turned on, the compressed air regulated by the pressure regulating and flow stabilizing unit 300 is accurately delivered to the cylinder of the pneumatic scissors 400 to provide power for the shearing action.

[0024] The pressure regulating and flow stabilizing unit 300 is used to receive the pressure setting command from the control module 100, regulate the pressure of the input compressed air, output a stable air source that meets the preset pressure threshold, and collect the instantaneous air pressure data at the output end in real time. When the air pressure is lower than the threshold and the deviation is small, it performs step-by-step pressurization; when the air pressure is higher than the threshold and the deviation is large, it performs graded pressure reduction to ensure that the air pressure is stable within the preset pressure difference range.

[0025] The pneumatic shears 400 receive stable compressed air from the pneumatic drive unit 200. The cylinder piston rod moves under the action of air pressure, driving the cutting edge to close and applying shearing force to the sprue of the workpiece to complete the removal of the sprue. After shearing, as the solenoid valve closes and the air passage is vented, the cutting edge opens under the action of the reset mechanism, returning to the initial ready position, ready for the next shearing operation.

[0026] The time relay 110 is used to receive the timing parameters (first duration) from the control module 100 and to time the duration of the first drive signal in real time. When the internal timing duration is consistent with the first duration, it automatically feeds back a signal to the control module 100 or directly triggers the first drive signal to be cut off, so as to ensure that the pneumatic scissors 400 completes the cutting and resetting action within the preset duration and avoids excessive or insufficient action.

[0027] The cycle counter 120 is used to automatically increment the count after each preset water inlet shearing operation is completed, accurately record the number of shearings, and compare the current count with the preset total number of water inlets threshold in real time. When the count is greater than or equal to the threshold, a signal is fed back to the control module 100 to trigger the work cycle to stop, ensuring that all preset water inlets are sheared and avoiding missed or over-shearing.

[0028] This embodiment achieves precise setting and stable output of the working pressure of the pneumatic shears 400 through the coordinated control of the control module 100 and the pressure regulating and flow stabilizing unit 300, fundamentally solving the problem of uneven shearing force caused by air pressure fluctuations in traditional manual adjustment or non-steady flow control.

[0029] Furthermore, the control module 100 outputs a first drive signal to the pneumatic drive unit 200 for a fixed duration (first preset time) based on preset shearing timing parameters, ensuring that the stroke, shearing force, and action time of each shearing operation are highly consistent. This mechanism can flexibly adapt to the shearing requirements of sprues for workpieces of different specifications, significantly reducing quality problems such as workpiece damage or excessive sprue residue caused by parameter deviations, thereby ensuring the consistency and pass rate of batch-processed workpieces.

[0030] Upon receiving a start command, the control module 100 autonomously enters a preset automatic work cycle, fully executing the output shearing signal, driving the pneumatic shears 400 to shear, resetting the shears with a cut-off signal, waiting at intervals, and starting the shearing process at the next station, until all preset gate shearing is completed or a stop signal is received. Compared to the traditional manual operation method of starting and stopping sequentially and manually positioning, this embodiment completely eliminates the limitations of human efficiency, significantly shortens the overall shearing time for a single workpiece or multiple gates, is suitable for batch production scenarios, effectively improves the overall operating efficiency of the production line, and reduces the processing time cost per unit workpiece.

[0031] Furthermore, the pressure regulating and flow stabilizing unit 300, through dual regulation of compressed air pressure and flow rate, avoids instantaneous overload and wear on the internal components of the pneumatic scissors 400 caused by air pressure shock or unstable airflow. At the same time, the control module 100, through strict timing control (i.e., driving shearing at the first preset time and waiting at the second preset time interval), keeps the pneumatic scissors 400 in a cycle of working, resetting, and standby, effectively preventing overheating or fatigue failure caused by continuous high-intensity operation, thereby extending the service life of the pneumatic scissors 400 and the pneumatic drive unit 200, and reducing maintenance frequency and overall costs.

[0032] The control method of the present invention will be further described below with reference to the accompanying drawings.

[0033] Reference Figure 1 , Figure 1A flowchart of a sprue-cutting method based on a sprue-cutting machine is provided for an embodiment of the present invention. The method includes, but is not limited to, the following steps: Step S11: The control module performs an initialization operation, sets the working pressure of the pneumatic shears through the pressure regulating and flow stabilizing unit, and sets the shearing timing parameters in the control module. It should be noted that the control module precisely sets the working pressure of the pneumatic shears through the pressure regulating and flow stabilizing unit. It can match the optimal shearing pressure value according to the characteristics of the workpiece material (such as plastic and metal), sprue thickness and strength, so as to avoid problems such as workpiece deformation and cracking due to excessive pressure, or incomplete sprue shearing and excessive residue due to insufficient pressure. At the same time, the control module presets shearing sequence parameters (such as the first preset shearing time and the second preset interval waiting time) to clarify the working cycle and action rhythm of the pneumatic shears. This ensures that the shearing operation follows standardized parameters from the beginning, laying the core foundation for the consistency and stability of subsequent automated cyclic shearing, and effectively avoiding processing quality risks caused by parameter fluctuations.

[0034] It should be noted that the operating pressure and shearing timing parameters are all set through the control module, without requiring any modification to the equipment's mechanical structure. These parameters can be flexibly adjusted according to the sprue design of different products (e.g., single-sprue, multi-station sprue) and production cycle requirements. For example, for thick-walled sprues, the working pressure can be appropriately increased and the first preset shearing time extended; for thin-walled, easily damaged workpieces, the pressure can be reduced and the shearing action duration shortened; for multi-station continuous processing, the second preset interval waiting time can be optimized to match the production line's flow rhythm. This setting method allows the fully automatic sprue cutting machine to adapt to the sprue cutting needs of various product specifications without replacing core components, significantly improving the equipment's process compatibility and application range, and reducing equipment changeover costs in multi-variety sprue cutting scenarios.

[0035] In step S12, the control module enters a preset automatic working cycle according to the start command and outputs a shearing signal. The control module continuously outputs a first drive signal for a first preset time to the pneumatic drive unit according to the shearing timing parameters. It should be noted that the control module outputs a drive signal to the pneumatic drive unit for a duration of a first preset time based on preset shearing timing parameters, thereby strictly limiting the duration of a single shearing action of the pneumatic shears within a reasonable range. This ensures that the contact time between the blade of the pneumatic shears and the sprue is consistent with the shearing stroke height in each operation, effectively preventing excessive workpiece compression or deformation caused by excessively long drive signal durations, and also preventing problems such as incomplete sprue shearing and excessive residue caused by excessively short shearing times. Whether in a single-station, single-operation scenario or a multi-station, continuous processing scenario, standardized shearing operations can be achieved, significantly improving the consistency of sprue treatment quality for batches of workpieces and reducing the risk of defective products caused by timing fluctuations.

[0036] Furthermore, the signal design based on the first preset time allows the system to flexibly set the optimal shearing action duration according to the actual specifications of the sprue (such as thickness and strength) and the mechanical characteristics of the pneumatic shears, preventing the pneumatic shears from continuing to be pressurized or idling after completing effective shearing. This reduces ineffective friction between the blade and the workpiece, suppresses redundant cylinder movements, and thus reduces overall mechanical wear on the pneumatic shears and pneumatic drive unit. Simultaneously, this mechanism also eliminates instantaneous overload and impact on the equipment caused by irregular output of the first drive signal, effectively protecting the core components of the pneumatic shears, ultimately extending equipment lifespan, reducing maintenance frequency, and lowering overall costs.

[0037] In step S13, the pneumatic drive unit responds to the first drive signal to drive the pneumatic shears with compressed air regulated by the pressure regulating and flow stabilizing unit to perform shearing operations on the sprue of the workpiece. It should be noted that the pneumatic drive unit can respond quickly to the first drive signal issued by the control module, efficiently delivering compressed air, precisely processed by the pressure regulating and flow stabilizing unit, to the pneumatic shears, thereby providing them with a stable driving force that perfectly matches the preset parameters. This pneumatic transmission mechanism avoids the lag and wear problems common in mechanical transmissions, ensuring that the pneumatic shears quickly reach the preset shearing force and action speed within the first preset time, and accurately act on the target position of the sprue. This effectively overcomes the drawbacks of untimely shearing and insufficient shearing force caused by power delay or attenuation, significantly improving the reliability and effectiveness of the operation.

[0038] The compressed air, after being processed by the pressure regulating and flow stabilizing unit, maintains a highly constant pressure and flow rate. Based on this stable air source, the pneumatic drive unit can provide a continuous and uniform driving force to the pneumatic shears, ensuring that the blade force remains consistent throughout the shearing process. Furthermore, for sprue nozzles of different materials (such as plastics and metals), thicknesses, and strengths, operators can preset the appropriate working pressure. With the assistance of the pneumatic drive unit, this allows for thorough shearing of thick-walled, high-strength sprue nozzles while avoiding excessive pressure that could cause deformation or mechanical damage to thin-walled, fragile workpieces. This significantly enhances the adaptability and process inclusiveness of the fully automatic sprue nozzle shearing machine to diverse sprue nozzle processing needs.

[0039] Step S14: When the first preset time ends, the control module cuts off the first drive signal, the pneumatic drive unit is turned off, and the pneumatic scissors are reset to the ready state. It should be noted that when the first preset time (i.e., the optimal shearing duration) ends, the control module will immediately cut off the first drive signal, causing the pneumatic drive unit to stop supplying air. The pneumatic shears will then cease operation and quickly reset. This strictly limits the duration of a single shearing action by the pneumatic shears, effectively preventing continuous pressure or scraping of the workpiece by the blades due to excessive timeout. This prevents over-processing problems such as deformation of thin-walled parts and cracking of brittle materials, ensuring precise application of the shearing operation to the sprue area and guaranteeing the processing accuracy and appearance integrity of the workpiece.

[0040] After the first drive signal is cut off, the pneumatic shears automatically reset to the ready state without manual intervention, achieving seamless connection with the interval waiting period (second preset time) set by the control module. Compared with the traditional equipment that relies on manual or natural reset, this embodiment significantly shortens the non-operation time between two cuts, ensuring the continuous and orderly progress of the automated process of cutting, resetting, and the next cut, effectively avoiding production rhythm disorder caused by reset delay, thereby further improving the overall efficiency of batch processing.

[0041] Furthermore, the control module promptly cuts off the gas supply after shearing, avoiding continuous waste of compressed air and helping to reduce system energy consumption. Simultaneously, the immediate reset of the pneumatic shears reduces the ineffective contact time between the blade and the workpiece, effectively extending the overall service life of the equipment and reducing maintenance frequency and operating costs.

[0042] Step S15: The control module enters the second preset time interval waiting period; It should be noted that the second preset time interval can be flexibly set according to the actual working conditions of the production line, such as the workpiece conveying speed and the spacing between multiple workstations. This allows sufficient time for the workpiece to complete workstation switching and positioning calibration after the pneumatic shears reset, avoiding problems such as shearing position deviation, missed shearing of the sprue, or workpiece collision caused by starting the next shearing operation before the workpiece is in place. This design achieves precise coordination between the sprue shearing operation and the production line conveying process, ensuring smooth connection between processes in multi-workstation, continuous production scenarios, and improving the orderliness and stability of the overall production process.

[0043] Step S16: After the second preset time ends, the shearing signal is output again to start the shearing cycle for the next station nozzle until all preset nozzles are sheared or a stop signal is received.

[0044] It should be noted that after the second preset time expires, the control module will automatically restart the shearing signal, initiating the shearing cycle of the next station without manual intervention, thus forming a complete automated closed loop of shearing, resetting, waiting, and re-shearing. This eliminates the reliance on manual triggering at each station in traditional operations, making it particularly suitable for multi-station, high-volume sprue shearing scenarios. It enables continuous, uninterrupted standardized operations, significantly shortening the overall shearing time for multi-station sprues, improving the overall efficiency of the production line, and effectively reducing the processing time and labor costs per unit workpiece.

[0045] Furthermore, the control module automatically restarts the shearing cycle based on preset logic, ensuring that the start time, shearing parameters (such as pressure and duration), and intervals of each cycle remain strictly consistent. This fundamentally avoids response delays or parameter execution deviations that may occur during manual operation. Whether it is continuous processing of multiple nozzles on the same workpiece or batch processing of different workpieces, the process standards for each shearing operation are highly uniform. This effectively avoids quality problems such as shearing position shifts, uneven nozzle residue, or workpiece damage caused by fluctuations in cycle rhythm, comprehensively improving the consistency and pass rate of batch-processed products.

[0046] It should be noted that this embodiment only requires initialization through the control module (setting working pressure and shearing timing parameters) to trigger automatic cycling via a start command. Operators do not need complex equipment debugging or manual operation skills, reducing personnel training costs and lowering the operational threshold. Simultaneously, the shearing timing parameters (first preset time, second preset time) can be flexibly adjusted according to workpiece type and sprue specifications, without requiring significant modifications to the equipment structure, thus adapting to the production needs of different products and improving process flexibility. Furthermore, fully automated operation reduces direct contact between operators and pneumatic shears (high-speed moving parts), avoiding the risk of mechanical injury that may occur during manual operation and improving the safety of production operations.

[0047] Additionally, in one embodiment, reference is made to Figure 2 ,exist Figure 1 In step S13 of the illustrated embodiment, the pneumatic drive unit responds to the first drive signal and includes, but is not limited to, the following steps: Step S21: The solenoid valve starts in response to the first drive signal, establishing a flow path for compressed air; Step S22: Compressed air is delivered to the cylinder of the pneumatic scissors at a set stable working pressure. In step S23, the piston rod of the cylinder moves under air pressure and drives the blade of the pneumatic scissors to close, completing the shearing process.

[0048] It should be noted that the solenoid valve responds instantaneously upon receiving the first drive signal, rapidly establishing an efficient airflow path, ensuring that the stable compressed air processed by the pressure regulating and flow stabilizing unit is delivered losslessly to the pneumatic scissor cylinder. This effectively avoids the power transmission delay and pressure attenuation problems commonly found in traditional air circuits.

[0049] Driven by constant air pressure, the cylinder piston rod moves at a constant speed, causing the shearing edge to close precisely and smoothly. This process ensures that the shearing force is stably applied to the nozzle section, fundamentally solving problems such as incomplete shearing, edge jamming, or workpiece damage caused by power fluctuations, and significantly improving the reliability and certainty of a single shearing action.

[0050] Furthermore, through the synergistic effect of the pressure regulating and flow stabilizing unit, the control module can match the optimal working pressure for different sprue specifications (such as thickness and material). This ensures that thick-walled sprues are completely sheared while effectively preventing thin-walled workpieces from being squeezed, deformed, or mechanically damaged due to overpressure. This allows for precise control of the sprue residual height and the integrity of the workpiece appearance, ensuring a high degree of consistency in batch processing quality.

[0051] As a key actuator, the solenoid valve's operation is entirely controlled by the preset logic of the control module, deeply integrated into the automated closed loop of parameter preset, signal output, and action execution. Its opening and closing are strictly synchronized with the timing parameters of the control module, ensuring seamless connection between signal output, blade closure, and shearing completion, effectively supporting the collaborative operation of multi-station cyclic shearing and the overall stability of the fully automatic sprue cutter.

[0052] Additionally, in one embodiment, reference is made to Figure 3 ,exist Figure 1 Step S12 of the illustrated embodiment, which involves continuously outputting a first drive signal to the pneumatic drive unit for a first preset time, also includes, but is not limited to, the following steps: Step S31: Set the first drive signal to the first duration to ensure that the pneumatic shears complete a single cutting and resetting action; Step S32: Set the first drive signal to the second duration so that the workpiece pneumatic shears can move and be positioned between the sprue stations. Step S33: The control module enters the preset automatic working cycle according to the start command.

[0053] It should be noted that this embodiment achieves precise timing control of the entire shearing operation process by setting a first duration and a second duration respectively. The first duration fully covers the action cycle of blade closing, shearing, and resetting, ensuring that the pneumatic shears complete effective shearing and safe resetting within the duration of the first drive signal. This prevents incomplete shearing or incomplete resetting due to insufficient duration, and also avoids wasted air and component wear caused by excessive signal duration. The second duration is dedicated to workpiece movement and precise positioning. Its setting value is strictly matched with the production line conveying rhythm, preventing incorrect or missed shearing caused by misalignment of workstations, and achieving seamless connection between shearing and workstation switching processes. By setting differentiated durations for different process characteristics—the shearing and resetting stage emphasizes compact and efficient movements, while the workstation movement stage focuses on rhythm matching—the collaboration of the two durations ensures that the shearing, movement, and re-shearing cycle is highly consistent with the production line rhythm, significantly reducing redundant time consumption between processes and improving batch production efficiency. At the same time, this precise timing control effectively reduces the ineffective movements and mechanical impact of the pneumatic shears, reducing equipment wear and maintenance costs, and achieving energy-saving operation. Furthermore, the control module can flexibly adjust the first duration according to the workpiece sprue specifications (size, material), and optimize the second duration according to the workpiece size and conveying speed. It can quickly adapt to the production of multiple specifications of products without hardware modification, significantly enhancing the process adaptability and comprehensive benefits of the fully automatic sprue cutter in multi-variety cutting scenarios.

[0054] Additionally, in one embodiment, reference is made to Figure 4 ,exist Figure 3 In step S33 of the illustrated embodiment, the control module enters a preset automatic working cycle according to the start command, and includes, but is not limited to, the following steps: Step S41: When the internal timing duration of the time relay is the same as the first duration, the first drive signal is automatically cut off; Step S42: The pneumatic scissors are de-energized and shut down, cutting off the flow path of compressed air, venting the gas inside the pneumatic scissors, and causing the blades of the pneumatic scissors to open. Step S43: When all preset sprues have completed shearing, stop the automatic working cycle.

[0055] It should be noted that this embodiment uses a time relay to achieve precise timing control, ensuring the efficiency and reliability of the shearing operation. The time relay matches its internal timing with a preset first duration, automatically cutting off the first drive signal after the pneumatic shears complete a single cycle of blade closing, shearing, and resetting. This avoids incomplete shearing or incomplete resetting due to premature signal interruption, and also prevents air waste and mechanical component fatigue caused by prolonged signal duration. After the first drive signal is cut off, the control module simultaneously closes the compressed air passage and discharges residual air from the cylinder, allowing the pneumatic shear blades to quickly return to the open state, providing standardized initial conditions for the next processing operation and significantly improving the consistency and reliability of the action execution.

[0056] During the reset phase, the pneumatic shears' blades quickly return to their original position, providing a safe operating space for workpiece removal and positioning, effectively preventing the risk of mechanical interference. Simultaneously, the precise timing function of the time relay ensures that the operation rhythm of shearing, reset, and station switching is highly synchronized with the production line's conveyor flow, guaranteeing the orderly progress of multi-station cyclic shearing. Once the control module detects that all preset sprue shearing operations have been completed, it automatically terminates the work cycle. This achieves fully automated management of batch processing and intelligent shutdown without manual intervention, significantly improving the collaborative efficiency and intelligence level of the fully automatic sprue shearing machine's production system.

[0057] Furthermore, the automatic switching of the drive signal is achieved through timing matching via a time relay, eliminating the need for complex external sensors or manual operation. This simplifies the control module's logic and improves operational reliability. The first duration parameter can be flexibly adjusted according to workpiece specifications and shearing difficulty, giving the fully automatic sprue cutter the ability to adapt to different sprue characteristics and production cycles. Combined with the automatic stop function based on a preset quantity, the control module can precisely manage the processing flow without manual counting or frequent start-stop operations, significantly improving the adaptability and ease of operation of the fully automatic sprue cutter in scenarios involving multiple product types and batches of sprue cutters.

[0058] Additionally, in one embodiment, reference is made to Figure 5 ,exist Figure 4 Step S43 of the illustrated embodiment, when all preset sprues have completed shearing, stops the automatic work cycle and includes, but is not limited to, the following steps: Step S51: Reset the cycle counter. When the preset water inlet is cyclically sheared, the cycle counter is incremented once. Step S52: Compare the current value of the loop counter with the preset threshold for the total number of water inlets; Step S53: When the current value of the cycle counter is greater than or equal to the threshold of the total number of water inlets, the automatic working cycle is stopped.

[0059] It should be noted that after initialization and reset, the cycle counter automatically increments with each shearing action of the preset nozzles and compares it in real time with the preset total nozzle threshold, thereby accurately monitoring the progress of the shearing operation. When the current value of the cycle counter reaches or exceeds the total nozzle threshold, the control module will automatically terminate the work cycle, ensuring that all preset nozzles are completely processed. This effectively avoids quality problems such as missed or insufficient shearing that may be caused by manual counting errors, and also eliminates workpiece damage or equipment idling caused by over-shearing, strongly guaranteeing the accuracy and completeness of batch processing tasks.

[0060] The counting control mechanism in this embodiment achieves fully automated management of the entire process, from processing execution and progress monitoring to shutdown upon reaching the target, eliminating the need for operators to monitor the number of shearing operations in real time or manually stop the equipment. Compared to traditional operation modes that rely on manual counting and manual shutdown, this embodiment completely eliminates the dependence on continuous human attention, significantly reducing production errors caused by human negligence and alleviating the labor intensity and on-site management costs for operators. This makes the fully automatic sprue shearing machine effectively applicable to high-volume, multi-station sprue shearing scenarios, improving the automation and intelligence level of the sprue shearing process.

[0061] It should be noted that the threshold for the total number of sprue marks can be flexibly set according to the specific needs of different products. For example, for a task requiring the cutting of 3 sprue marks on a single workpiece, the threshold can be set to 3; while for batch processing of 100 single-sprue workpieces, the threshold can be set to 100. This parameterized setting method allows the fully automatic sprue cutter to quickly adapt to diverse production scenarios such as single workpiece with multiple sprue marks and multiple workpieces with single sprue marks without requiring mechanical structure modifications or control logic adjustments. It demonstrates excellent process compatibility and production flexibility, significantly reducing equipment changeover costs and production line adjustment time in the process of cutting sprue marks for multiple product varieties.

[0062] Additionally, in one embodiment, reference is made to Figure 6 ,exist Figure 1 After step S11 in the illustrated embodiment, and before step S12 (before the control module enters the preset automatic working cycle according to the start command), the following steps are included, but are not limited to: Step S61: Real-time acquisition of the current pressure value of compressed air, and comparison of the current pressure value with the minimum working pressure threshold of the pneumatic scissors; Step S62: When the current pressure value is greater than or equal to the minimum working pressure threshold, the current pressure value is determined to be valid, and the control module sends a first drive signal to the pneumatic shears. Step S63: When the current pressure value is lower than the minimum working pressure threshold, the control module generates an insufficient air pressure alarm signal and locks the air pressure drive unit.

[0063] It is important to note that stable and adequate air pressure is a key factor in ensuring the normal operation of pneumatic shears. Air pressure directly determines the shearing force of the pneumatic shears. Insufficient air pressure can easily lead to incomplete closure of the blade and insufficient shearing force, resulting in quality problems such as sprue residue, workpiece deformation, or even cracking. The control module, through a real-time pressure monitoring mechanism, ensures that the pneumatic shears are only allowed to start shearing when the air pressure is within the specified range. This guarantees sufficient power for each operation to complete sprue removal, effectively improving product quality consistency and yield.

[0064] Furthermore, when the control module detects that the air pressure is lower than the safety threshold, it will automatically lock the pneumatic drive unit to prevent the pneumatic scissors from operating under abnormal conditions, thereby significantly reducing component fatigue and failure risk and extending the overall service life of the pneumatic scissors.

[0065] Furthermore, the monitoring mechanism in this embodiment also features fault warning and safety protection functions. Insufficient air pressure in pneumatic scissors often stems from problems such as air compressor malfunction, pipeline leaks, or pressure regulating valve failure, which are difficult to detect in real time using traditional manual monitoring. This embodiment can generate an alarm signal the moment an abnormal pressure occurs, promptly alerting operators to intervene and prevent the fault from escalating, shortening troubleshooting and repair time, and minimizing the impact on production schedules. Simultaneously, the control module forcibly locks the equipment in abnormal conditions to prevent mechanical or personal safety accidents caused by blade jamming or loss of control of the pneumatic scissors. Combined with the alarm signal, this further enhances the safety of the working environment by alerting on-site personnel.

[0066] Additionally, in one embodiment, reference is made to Figure 7 ,exist Figure 1 Step S13 of the illustrated embodiment, in order to drive the pneumatic scissors with compressed air regulated by the pressure regulating and flow stabilizing unit, also includes, but is not limited to, the following steps: Step S71: Real-time acquisition of the current air pressure value of the compressed air flowing through the pressure regulating and flow stabilizing unit, wherein the current air pressure value is the instantaneous pressure data of the compressed air at the output end of the pressure regulating and flow stabilizing unit; Step S72: When the current air pressure value is lower than the preset air pressure threshold and the difference between the current air pressure value and the air pressure threshold is less than the first pressure difference range, the pressure regulating and flow stabilizing unit performs a step-by-step pressurization operation on the compressed air until the current air pressure value reaches the second pressure difference range of the air pressure threshold, and then the pressure regulating and flow stabilizing unit stops operating. Step S73: When the current air pressure value is higher than the air pressure threshold and the difference is greater than the first pressure difference range, the pressure regulating and flow stabilizing unit performs a graded pressure reduction operation on the compressed air and simultaneously feeds back the reduced air pressure data to the control module in real time until the current air pressure value stabilizes within the second pressure difference range of the air pressure threshold, at which point the pressure regulating and flow stabilizing unit stops operating.

[0067] It should be noted that the pressure regulating and flow stabilizing unit achieves precise and stable pressure control by monitoring the output air pressure data in real time and adopting differentiated adjustment strategies based on the deviation range. When the detected air pressure is lower than the set threshold and the deviation is small, the control module gradually restores the pressure using a stepped pressurization method, avoiding the impact of instantaneous pressurization on the air circuit and actuator. When the air pressure is higher than the threshold and the deviation is large, a graded pressure reduction program is initiated to ensure that the pressure smoothly returns to the target range. This intelligent adjustment mechanism keeps the output air pressure stable within the preset second pressure difference range, providing a continuous and uniform driving force for the pneumatic shears. This fundamentally solves the problem of unstable shearing force caused by air pressure fluctuations, effectively preventing quality defects such as sprue residue and workpiece damage, and ensuring a high degree of consistency in batch processing quality.

[0068] Compared to traditional single-rate regulation methods, the pressure regulating and flow stabilizing unit precisely matches the regulation strategy according to the degree of air pressure deviation. This avoids over-regulation and pressure oscillation under small deviation conditions while ensuring rapid response and efficient recovery under large deviation conditions. Stepped pressurization ensures the stability of the pneumatic shears while achieving rapid compensation for small pressure losses; staged depressurization enables controllable pressure relief for large overpressures. Combined with real-time data feedback, this forms a traceable and correctable closed-loop control system. Even under dynamic conditions such as air compressor fluctuations or minor leaks in the air circuit, it can still maintain rapid air pressure stability, ensuring the continuity and stability of shearing operations.

[0069] The stepped pressurization effectively eliminates damage to critical components of the pneumatic scissors caused by instantaneous high-pressure impacts, significantly reducing component fatigue wear. The staged pressure reduction mechanism prevents negative pressure in the air circuit and water hammer effect caused by sudden pressure drops, avoiding potential malfunctions such as pipe rupture and loose joints. Simultaneously, the continuously stable air pressure environment prevents the pneumatic scissors from operating under overload conditions due to abnormal pressure, effectively reducing the risks of cylinder jamming and seal aging. This significantly extends the service life of the air circuit system and actuators, reducing equipment maintenance frequency and overall operating costs.

[0070] like Figure 8 As shown, Figure 8 This is a structural diagram of a sprue-cutting device based on a sprue-cutting machine according to an embodiment of the present invention. The present invention also provides a sprue-cutting device based on a sprue-cutting machine, comprising: The processor 801 can be implemented using a general-purpose central processing unit (CPU), microprocessor, application specific integrated circuit (ASIC), or one or more integrated circuits, and is used to execute relevant programs to implement the technical solutions provided in the embodiments of this application. The memory 802 can be implemented as a read-only memory (ROM), static storage device, dynamic storage device, or random access memory (RAM). The memory 802 can store the operating system and other application programs. When the technical solutions provided in the embodiments of this specification are implemented through software or firmware, the relevant program code is stored in the memory 802 and is called and executed by the processor 801 to execute the sprue-cutting method based on the sprue-cutting machine of this application embodiment. The 803 input / output interface is used to implement information input and output. The communication interface 804 is used to enable communication and interaction between this device and other devices. Communication can be achieved through wired means (such as USB, network cable, etc.) or wireless means (such as mobile network, WIFI, Bluetooth, etc.). Bus 805 transmits information between various components of the device (e.g., processor 801, memory 802, input / output interface 803, and communication interface 804); The processor 801, memory 802, input / output interface 803, and communication interface 804 are connected to each other within the device via bus 805.

[0071] This application also provides an electronic device, including a sprue-cutting device based on a sprue-cutting machine as described above.

[0072] This application embodiment also provides a storage medium, which is a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it implements the above-described sprue-cutting method based on a sprue-cutting machine.

[0073] Memory, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs and non-transitory computer-executable programs. Furthermore, memory may include high-speed random access memory, and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, memory may optionally include memory remotely located relative to the processor, and these remote memories can be connected to the processor via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof. The device embodiments described above are merely illustrative, and the units described as separate components may or may not be physically separate, and may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0074] It will be understood by those skilled in the art that all or some of the steps and systems in the methods disclosed above can be implemented as software, firmware, hardware, and suitable combinations thereof. Some or all of the physical components can be implemented as software executed by a processor, such as a central processing unit, digital signal processor, or microprocessor, or as hardware, or as an integrated circuit, such as an application-specific integrated circuit. Such software can be distributed on a computer-readable medium, which can include computer storage media (or non-transitory media) and communication media (or transient media). As is known to those skilled in the art, the term computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information (such as computer-readable instructions, data structures, program modules, or other data). Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc (DVD) or other optical disc storage, magnetic cartridges, magnetic tape, disk storage or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible to a computer. Furthermore, as is known to those skilled in the art, communication media typically include computer-readable instructions, data structures, program modules, or other data in modulated data signals such as carrier waves or other transmission mechanisms, and may include any information delivery medium.

[0075] The above provides a detailed description of the preferred embodiments of the present invention. However, the present invention is not limited to the above embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention. All such equivalent modifications or substitutions are included within the scope defined by the claims of the present invention.

Claims

1. A method for shearing nozzles based on a nozzle shearing machine, characterized in that, The method is applied to a fully automatic sprue cutter, which includes a control module, a pneumatic drive unit, a pressure regulating and flow stabilizing unit, and pneumatic shears. The control module is connected to the pneumatic drive unit, the pressure regulating and flow stabilizing unit, and the pneumatic shears. The control module performs an initialization operation, sets the working pressure of the pneumatic shears through the pressure regulating and flow stabilizing unit, and sets the shearing timing parameters in the control module; The control module enters a preset automatic working cycle according to the start command and outputs a shearing signal. The control module continuously outputs a first drive signal for a first preset time to the pneumatic drive unit according to the shearing timing parameters. The pneumatic drive unit responds to the first drive signal to drive the pneumatic shears with compressed air regulated by the pressure regulating and flow stabilizing unit to perform shearing operations on the sprue of the workpiece. When the first preset time ends, the control module cuts off the first drive signal, the pneumatic drive unit shuts down, and the pneumatic scissors reset to the ready state; The control module enters a second preset time interval waiting period; After the second preset time ends, the shearing signal is output again to start the shearing cycle for the next station nozzle until all preset nozzles are sheared or a stop signal is received.

2. The method for cutting water nozzles based on a water nozzle cutting machine according to claim 1, characterized in that, The pneumatic drive unit is equipped with a solenoid valve, and the pneumatic drive unit responds to the first drive signal, including: The solenoid valve is activated in response to the first drive signal to establish the flow path of the compressed air; Compressed air is delivered to the cylinder of the pneumatic scissors at a set stable working pressure; The piston rod of the cylinder moves under air pressure and drives the blade of the pneumatic scissors to close, thus completing the shearing process.

3. The method for cutting water nozzles based on a water nozzle cutting machine according to claim 1, characterized in that, The control module continuously outputs a first drive signal for a first preset time to the pneumatic drive unit according to the shearing timing parameters, including: The first drive signal is set to a first duration to ensure that the pneumatic scissors complete a single cutting and resetting action. The first drive signal is set to a second duration so that the workpiece can move and be positioned between the sprue stations. The control module enters a preset automatic working cycle according to the start command.

4. The method for cutting water nozzles based on a water nozzle cutting machine according to claim 3, characterized in that, The control module is also equipped with a time relay. The control module enters a preset automatic working cycle according to a start command, including: When the internal timing duration of the time relay is the same as the first duration, the first drive signal is automatically cut off; The pneumatic scissors shut down when the power is off, cutting off the flow path of the compressed air, expelling the gas inside the pneumatic scissors, and causing the blades of the pneumatic scissors to open. The automatic work cycle stops when all the preset nozzles have completed shearing.

5. The method for cutting water nozzles based on a water nozzle cutting machine according to claim 4, characterized in that, The control module is also equipped with a cycle counter. The step of stopping the automatic working cycle when all the preset water inlets have completed shearing includes: The cycle counter is reset, and when the preset water inlet is cyclically sheared, the cycle counter is incremented once; The current value of the cycle counter is compared with a preset threshold for the total number of water inlets; When the current value of the cycle counter is greater than or equal to the threshold value of the total number of water inlets, the automatic working cycle stops.

6. The method for cutting water nozzles based on a water nozzle cutting machine according to claim 1, characterized in that, Before the control module enters a preset automatic work cycle according to the start command, the method further includes: The current pressure value of the compressed air is collected in real time, and the current pressure value is compared with the minimum working pressure threshold of the pneumatic scissors. When the current pressure value is greater than or equal to the minimum working pressure threshold, the current pressure value is determined to be valid, and the control module sends the first drive signal to the pneumatic shears. When the current pressure value is lower than the minimum working pressure threshold, the control module generates an insufficient air pressure alarm signal and locks the air pressure drive unit.

7. The method for cutting water nozzles based on a water nozzle cutting machine according to claim 1, characterized in that, The method of driving the pneumatic shears with compressed air regulated by the pressure regulating and flow stabilizing unit includes: The current air pressure value of the compressed air flowing through the pressure regulating and flow stabilizing unit is collected in real time, wherein the current air pressure value is the instantaneous pressure data of the compressed air at the output end of the pressure regulating and flow stabilizing unit; When the current air pressure value is lower than the preset air pressure threshold, and the difference between the current air pressure value and the air pressure threshold is less than the first pressure difference range, the pressure regulating and flow stabilizing unit performs a step-by-step pressurization operation on the compressed air until the current air pressure value reaches the second pressure difference range of the air pressure threshold, at which point the pressure regulating and flow stabilizing unit stops operating. When the current air pressure value is higher than the air pressure threshold and the difference is greater than the first pressure difference range, the pressure regulating and flow stabilizing unit performs a graded pressure reduction operation on the compressed air and simultaneously feeds back the reduced air pressure data to the control module in real time until the current air pressure value stabilizes within the second pressure difference range of the air pressure threshold, at which point the pressure regulating and flow stabilizing unit stops operating.

8. A sprue-cutting device based on a sprue-cutting machine, characterized in that, It includes at least one control processor and a memory for communicatively connecting to the at least one control processor; the memory stores instructions executable by the at least one control processor, which, when executed by the at least one control processor, enable the at least one control processor to perform the sprue-cutting method based on a sprue-cutting machine as described in any one of claims 1 to 7.

9. An electronic device, characterized in that, The device includes the sprue-cutting device based on the sprue-cutting machine as described in claim 8.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-executable instructions for causing a computer to perform the sprue-cutting method based on a sprue-cutting machine as described in any one of claims 1 to 7.

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