Full-automatic feeding, positioning and heat-shrinking packaging integrated machine for grinding wheel piece

Abstract

This invention discloses a fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels, comprising a frame assembly (1), an automatic feeding module (2), an adaptive positioning module (3), a film sealing and cutting module (4), an adjustable speed heat-shrink module (5), a finished product discharge module (6), and an electrical control system (7). The automatic feeding module (2), adaptive positioning module (3), film sealing and cutting module (4), adjustable speed heat-shrink module (5), and finished product discharge module (6) are sequentially installed on the frame assembly (1) along the conveying direction. The electrical control system (7) is electrically connected to each module to achieve coordinated operation of each module. Through modular integrated design, adaptive precise positioning, stepless speed-adjustable heat shrinking, and intelligent collaborative control, the machine achieves fully automated packaging of grinding wheels from feeding to discharging without human intervention, significantly improving packaging accuracy, production efficiency, and product qualification rate.

Description

Technical Field

[0001] This invention relates to the field of automated packaging equipment technology, specifically to a fully automatic feeding, positioning, and heat shrink packaging machine for abrasive wheels. Specifically, it relates to a fully automatic feeding, precise positioning, and heat shrink molding integrated packaging equipment for abrasive products such as resin grinding wheels, diamond grinding discs, and cutting discs. More particularly, it relates to a heat shrink packaging machine that can adapt to different diameter specifications, supports single and multi-piece stacking, and operates continuously without human intervention throughout the entire process. Background Technology

[0002] Grinding wheels are indispensable grinding and cutting tools in machining, construction, hardware manufacturing, ship repair, and steel processing, with massive production volumes and numerous specifications. After the grinding wheels are manufactured, the packaging process is a crucial step in ensuring the product's appearance, rust prevention, moisture protection, impact protection, and facilitating warehousing and transportation. With the increasing automation of manufacturing, traditional manual packaging methods can no longer meet the demands of large-scale, high-efficiency, and high-quality production.

[0003] The following technical problems are currently prevalent in the packaging of grinding wheels in the industry:

[0004] First, the feeding and positioning processes are highly dependent on manual labor. The placement of the grinding wheel is highly random, and phenomena such as center offset, angle tilt, and edge misalignment occur frequently. This leads to inaccurate film positioning, uneven wrinkles in the film after heat shrinking, local exposed edges, and a high rate of packaging scrap. The positioning error is usually above 2-5mm, making it difficult to achieve standardized packaging.

[0005] Secondly, the processes are highly separated. Feeding, positioning, film wrapping, heat shrinking, and unloading are all completed by different equipment or manual labor. Transfer between processes is time-consuming and labor-intensive, the production rhythm is not continuous, the output per shift is low, the labor cost accounts for a high proportion, and there is a risk of workplace injury.

[0006] Third, the positioning fixtures are mostly fixed structures, which can only be used with a single diameter grinding wheel. Changing product specifications requires disassembling and replacing the fixture and adjusting the conveyor channel. The changeover time is as long as 30 minutes or more. They have poor versatility and cannot meet the needs of multi-variety, small-batch, and rapid production changeover.

[0007] Fourth, heat shrink tunnels often adopt a constant temperature and speed design, resulting in uneven hot air circulation and large temperature fluctuations. This makes it impossible to match the optimal heat shrink process for grinding wheels of different thicknesses, diameters, and stacking quantities, which can easily lead to quality defects such as inadequate film shrinkage, excessive shrinkage causing burns, and localized blistering.

[0008] Fifth, the continuous operation capability is poor. Manual feeding is prone to material stacking and jamming. The equipment lacks intelligent detection and error correction functions, resulting in a high downtime rate and making it difficult to achieve 24-hour unattended continuous production.

[0009] Sixth, there is serious waste of film material, inaccurate control of film size during manual film application, unstable sealing and cutting positions, a lot of scrap material, and high packaging costs.

[0010] In existing publicly available technologies, some grinding wheel packaging equipment only achieves semi-automation, such as manual feeding + automatic heat shrinking, or simple positioning + manual wrapping, without forming a fully integrated process; the positioning mechanism lacks adaptive adjustment capability; the heat shrinking system lacks precise closed-loop temperature control; and the control system has a low level of intelligence, failing to fundamentally solve the industry's pain points. Therefore, developing a high-precision, high-efficiency, highly compatible, and fully automated integrated heat shrink packaging machine for grinding wheels has become an urgent need for the abrasive and grinding tool industry. Summary of the Invention

[0011] This invention aims to address the problems of low positioning accuracy, process separation, poor compatibility, low efficiency, and unstable heat shrink quality in existing technologies by providing a fully automatic feeding, positioning, and heat shrink packaging machine for grinding wheels. Through modular integrated design, adaptive precise positioning, stepless speed regulation heat shrinking, and intelligent collaborative control, it achieves fully automated packaging of grinding wheels from feeding to discharging without human intervention, significantly improving packaging accuracy, production efficiency, and product qualification rate.

[0012] This invention provides an integrated automatic feeding, positioning, and heat shrink packaging machine for grinding wheels, comprising a frame assembly (1), an automatic feeding module (2), an adaptive positioning module (3), a film sealing and cutting module (4), an adjustable speed heat shrink module (5), a finished product discharge module (6), and an electrical control system (7); the automatic feeding module (2), the adaptive positioning module (3), the film sealing and cutting module (4), the adjustable speed heat shrink module (5), and the finished product discharge module (6) are sequentially installed on the frame assembly (1) along the conveying direction; the electrical control system (7) is electrically connected to each module to realize the coordinated operation of each module.

[0013] Preferably, the adaptive positioning module (3) includes a positioning platform, a slotted three-jaw centering fixture, a diameter adaptive adjustment mechanism, an angle correction mechanism, and a vacuum adsorption unit; the surface of the positioning platform is uniformly distributed with vacuum adsorption holes, and the vacuum adsorption unit includes a vacuum generator and an adsorption pipeline.

[0014] Preferably, the diameter adaptive adjustment mechanism consists of a stepper motor, a precision ball screw, a linear slider, and a synchronous transmission assembly. The stepper motor drives the precision ball screw to rotate, thereby causing the three-jaw chuck to synchronously extend and retract radially.

[0015] Preferably, the three jaws of the slotted three-jaw centering fixture are evenly distributed at 120°, each jaw is provided with a V-shaped slot, and a 3mm thick wear-resistant polyurethane buffer pad is pasted on the inner wall of the slot; the angle correction mechanism consists of a miniature rotary cylinder and an angle detection photoelectric sensor.

[0016] Preferably, the adjustable speed heat shrink module (5) includes a double-layer heat shrink channel, a four-sided circulating hot air system, a Teflon conveyor chain, a frequency conversion speed control mechanism, and a temperature sensor; the heat shrink channel is made of double-layer 304 stainless steel, with 50mm thick high-temperature resistant aluminum silicate insulation cotton in the middle; the four-sided circulating hot air system consists of 2 centrifugal fans, 8 sets of stainless steel electric heating tubes, and four-sided air nozzles; the frequency conversion speed control mechanism is used to drive the conveyor chain in a stepless adjustment manner within the speed range of 0–15m / min.

[0017] Preferably, the film sealing and cutting module (4) includes a film roll mounting bracket, a film feeding servo mechanism, a tension adjusting roller, a longitudinal sealing heating strip, a transverse sealing cutter, a film cutting cylinder, and a waste recycling mechanism; the film feeding servo mechanism is driven by a servo motor to feed a precision film feeding roller; the temperature of the longitudinal sealing heating strip is adjustable within the range of 0–300℃, and the width of the sealing edge is continuously adjustable within the range of 5–15mm; the transverse sealing cutter (45) is a high-temperature resistant alloy cutter, and the sealing and cutting time is adjustable within the range of 0.1–1s; a small roll roller is provided on the waste recycling mechanism for automatically recycling the sealing and cutting edge scraps.

[0018] Preferably, the automatic feeding module (2) includes an inclined storage bin, a double-roller differential speed dispensing mechanism, a servo pushing mechanism, a guide rail, and a positioning detection sensor; the inclined storage bin has an inclination angle of 15° and width adjustment plates on both sides to accommodate grinding wheels with a thickness of 1.0–10 mm; the double-roller differential speed dispensing mechanism achieves single-sheet dispensing through the speed difference between the active roller and the driven roller; the servo pushing mechanism consists of a servo electric cylinder, a linear guide rail, and a polyurethane-coated pushing plate.

[0019] Preferably, the finished product discharge module (6) includes a discharge conveyor belt, a cooling air gun assembly, an air pressure regulating valve, a finished product collection frame, and a product counting sensor; the cooling air gun assembly is equipped with 4 adjustable angle air guns, and the compressed air pressure is adjustable within the range of 0.2–0.5 MPa; the finished product collection frame is lined with an EVA buffer pad; the product counting sensor is an optical fiber sensor, which can provide batch counting reminders.

[0020] Preferably, the electrical control system (7) includes a PLC programmable logic controller and an industrial touch screen controller, and has the functions of process parameter storage, automatic / manual mode switching, real-time monitoring, fault alarm and safety interlock; the safety interlock function includes safety door limit switch, emergency stop button, overload protection and over-temperature protection.

[0021] Preferably, it also includes a pneumatic system (8) and a safety protection system (9); the pneumatic system (8) includes an air compressor interface, an oil-water separator, a pressure regulating valve, a solenoid valve, a cylinder, and a vacuum generator; the safety protection system (9) includes a high-strength aluminum alloy frame composite acrylic transparent protective cover, a maintenance safety door, and a limit switch, wherein the machine stops immediately when the maintenance safety door is opened.

[0022] The beneficial effects of the method and system of the present invention are as follows:

[0023] 1. Improved positioning accuracy: Traditional manual positioning has an error of 2–5 mm, while the positioning repeatability of this invention is ≤ ±0.1 mm, which is more than 20 times more accurate. This completely solves the problems of misalignment of the film and uneven heat shrinkage caused by positioning deviation, and increases the packaging qualification rate to more than 99.5%.

[0024] 2. Increased efficiency: Traditional manual packaging has an efficiency of 8-12 pieces / minute, while the present invention has a single-piece packaging efficiency of 45-55 pieces / minute and a multi-piece stacking efficiency of 8-10 packs / minute, which is 4-6 times more efficient. It can achieve 24-hour unattended continuous operation and greatly increase the output per shift.

[0025] 3. Improved compatibility: Traditional fixed clamps are only compatible with a single type of grinding wheel, resulting in long changeover times; the clamps of this invention have an adjustment range of φ75–φ400mm, covering the vast majority of grinding wheel specifications, with a changeover time of ≤5 minutes, making them suitable for multi-variety, small-batch production needs.

[0026] 4. Increased automation: Traditional packaging methods require manual participation in all stages, including feeding, positioning, film wrapping, and unloading, resulting in high labor costs. This invention achieves unmanned operation throughout the entire process, with a single device replacing 4-6 workers, significantly reducing labor costs and the risk of workplace injuries.

[0027] 5. Improved heat shrinking quality: Traditional heat shrinking equipment has a temperature fluctuation of ±10℃ and uneven hot air circulation, which can easily lead to problems such as poor film shrinkage and burns; This invention adopts PID closed-loop temperature control, with a temperature fluctuation of ±2℃ and four-sided circulating hot air, resulting in uniform film shrinkage and a flat and beautiful packaging appearance.

[0028] 6. Cost reduction: By reducing labor input, reducing membrane material waste (membrane material utilization rate ≥97%), and reducing packaging waste, the overall production cost is reduced by more than 30%, resulting in significant economic benefits. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the specific embodiments or related technologies of the present invention, the drawings used in the description of the specific embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the principle structure of the fully automatic feeding, positioning, and heat shrink packaging machine for grinding wheels provided in an embodiment of the present invention. Detailed Implementation

[0031] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] like Figure 1 As shown, this embodiment provides a fully automatic feeding, positioning, and heat shrink packaging machine for grinding wheels, which consists of a frame assembly (1), an automatic feeding module (2), an adaptive positioning module (3), a film sealing and cutting module (4), an adjustable speed heat shrink module (5), a finished product discharge module (6), an electrical control system (7), a pneumatic system (8), and a safety protection system (9). The modules are arranged sequentially along the horizontal conveying direction, resulting in a compact structure, reasonable layout, small footprint, and easy integration into the production line.

[0035] As a preferred embodiment, the frame assembly (1) serves as the installation base, is welded from Q235 square steel, and undergoes stress-relief annealing treatment, resulting in strong overall rigidity and no deformation during long-term operation; the surface is treated with electrostatic powder coating, making it corrosion-resistant, oil-resistant, and easy to clean; the bottom is equipped with M16 adjustable support feet and φ100mm universal casters with brakes, which can achieve precise leveling of the equipment and flexible movement and repositioning; a high-strength aluminum alloy frame + acrylic transparent protective cover is installed on the top of the frame, and maintenance safety doors are opened on both sides, equipped with limit switches, which stop the machine immediately when the door is opened, ensuring the safety of operators.

[0036] As a preferred implementation, the automatic feeding module (2) is used to store, distribute, and directionally transport grinding wheels to avoid stacking and jamming, ensuring stable and continuous feeding. The adaptive positioning module (3) is the core innovative unit, used to automatically center, correct angles, and vacuum-adsorb and fix grinding wheels of different diameters, solving the positioning deviation problem at its root. The film sealing and cutting module (4) is used to automatically transport, tension control, side sealing, and lateral sealing of the film to form an independent packaging unit. The adjustable speed heat shrinking module (5) uses circulating hot air to heat the film evenly, making it tightly adhere to the surface of the grinding wheel, achieving shaping and packaging. The finished product discharge module (6) is used to air-cool and shape the heat-shrinked product, transport it smoothly, and collect it with buffer, completing the entire packaging process. The electrical control system (7) adopts a PLC programmable logic controller + industrial touch screen to achieve speed synchronization, accurate positioning, temperature closed loop, and fault self-diagnosis for each module. The pneumatic system (8) is used to provide power for clamping, pushing, and correction actions, with stable operation and fast response. Safety protection system (9) provides comprehensive protection for equipment operation and operator safety.

[0037] In a preferred embodiment, the automatic feeding module (2) includes a storage bin, a dispensing mechanism, a pushing mechanism, a guide rail, and a positioning detection sensor. The storage bin adopts an inclined structure with an inclination angle of 15°, relying on gravity to allow the grinding wheel to slide down automatically; the storage bin has width adjustment plates on both sides, which are adjusted by a hand crank to drive the screw, adapting to grinding wheels with a thickness of 1.0–10 mm; the bottom of the storage bin is equipped with wear-resistant support strips to reduce friction damage to the grinding wheel; the dispensing mechanism adopts a double-roller differential dispensing structure, including a drive roller, a driven roller, and a dispensing drive motor. The drive roller rotates at a higher speed than the driven roller, separating the stacked grinding wheels through friction, ensuring that only one sheet enters the pushing station each time, thoroughly... The design completely eliminates the problem of feeding multiple or dual grinding wheels. The pushing mechanism consists of a servo cylinder, a linear guide rail, and a pusher plate. The stroke of the servo cylinder is adjustable from 100 to 500 mm, and the pushing speed is infinitely adjustable from 0 to 500 mm / s. The pusher plate is coated with polyurethane to prevent scratching the surface of the grinding wheel. The guide rail is made of stainless steel with a high-molecular-weight polyethylene guide strip on the inside to ensure straight and unobstructed feeding of the grinding wheel. The positioning sensor uses a diffuse reflection photoelectric switch, which triggers a positioning action after detecting the grinding wheel, achieving precise cycle control.

[0038] In a preferred embodiment, the adaptive positioning module (3) includes a positioning platform, a slotted three-jaw centering fixture, a diameter adaptive adjustment mechanism, an angle correction mechanism, a vacuum adsorption system, and a positioning sensor.

[0039] The positioning platform is made of high-strength aluminum alloy and has a hard anodized surface, making it smooth and wear-resistant. The positioning platform has evenly distributed φ3mm vacuum adsorption holes, which connect the vacuum generator and the adsorption pipeline. The adsorption force is adjustable from 0 to 0.08MPa, ensuring that the grinding wheel does not move after positioning.

[0040] The slotted centering fixture adopts a three-jaw symmetrical structure. Each jaw is equipped with a dedicated V-shaped slot. A 3mm thick wear-resistant polyurethane buffer pad is pasted on the inner wall of the slot, which not only ensures the centering accuracy but also avoids damage to the edge of the grinding wheel. The three jaws are evenly distributed at 120° and move radially synchronously to ensure that the center of the grinding wheel is completely aligned with the center of the packaging.

[0041] The diameter adaptive adjustment mechanism consists of a stepper motor, a precision ball screw, a linear slider, and a synchronous transmission assembly. The stepper motor receives the signal from the electronic control system (7), drives the screw to rotate, and drives the three jaws to contract inward or expand outward simultaneously. The adjustment range is φ75–φ400mm, the adjustment resolution is 0.1mm, and the adjustment time is ≤3s. The diameter of the grinding wheel can be directly input on the touch screen, and the clamp adjustment is automatically completed without the need for manual tool adjustment.

[0042] The angle correction mechanism consists of a miniature rotary cylinder and an angle detection photoelectric sensor. For a grinding wheel with a center mounting hole, the angle sensor detects the angle of the hole, and the miniature rotary cylinder drives the fixture to rotate slightly to correct the orientation of the grinding wheel, ensuring consistent packaging appearance. The angle correction accuracy is ±0.5°.

[0043] The positioning sensor is a high-precision laser displacement sensor that detects the position and diameter of the grinding wheel in real time and feeds it back to the electronic control system to form a closed-loop control, ensuring that the positioning repeatability accuracy is ≤ ±0.1mm.

[0044] As a preferred embodiment, the membrane sealing and cutting module (4) includes a membrane roll mounting bracket, a film feeding servo mechanism, a tension adjusting roller, a longitudinal sealing heating strip, a transverse sealing cutter, a film cutting cylinder, and a waste recycling mechanism;

[0045] The film roll holder is equipped with a heat shrink film roll with an inner diameter of 76mm and an outer diameter of ≤400mm, and is equipped with a corresponding film roll locking device for easy replacement.

[0046] The film feeding servo mechanism is driven by a servo motor to make a precision film feeding roller. The film feeding speed is synchronized with the overall machine conveying, and the film feeding length accuracy is ±0.5mm, so as to avoid the film material being too loose or too tight.

[0047] The tension adjusting roller adopts a spring floating structure to automatically maintain constant film tension and prevent stretching deformation;

[0048] The longitudinal sealing heating strip is a stainless steel heating tube with an adjustable temperature of 0–300℃ and a continuously adjustable sealing width of 5–15mm. It is equipped with a temperature detection sensor to achieve continuous and stable heat sealing on the side.

[0049] The horizontal sealing cutter uses a high-temperature resistant alloy blade, which is divided into an upper cutter and a lower cutter. The upper and lower cutters work together, the heating temperature is independently controlled, the sealing and cutting time is adjustable from 0.1 to 1 second, the seal is firm and airtight, and the cut edges are neat and burr-free.

[0050] The film-cutting cylinder is a two-way buffer cylinder, which ensures smooth and shock-free operation.

[0051] The waste recycling mechanism is equipped with a small rolling roller and a recycling drive motor, which is used to automatically recycle the cut and scrap materials and keep the equipment clean.

[0052] The film sealing and cutting module (4) described in this embodiment is compatible with various heat shrink films such as POF, PVC, and PE, with a film thickness of 0.03–0.12 mm, to meet different packaging strength requirements.

[0053] As a preferred embodiment, the adjustable speed heat shrink module (5) includes a heat shrink channel shell, a circulating hot air system, a conveyor chain, a frequency conversion drive mechanism, a temperature sensor, and a heat insulation layer.

[0054] The heat shrink tunnel shell is made of double-layer 304 stainless steel, with an inner layer thickness of 1.5mm and an outer layer thickness of 1.0mm. A 50mm thick high-temperature resistant aluminum silicate insulation layer is filled in between to form the heat insulation layer, reducing heat loss, improving thermal efficiency, and lowering energy consumption. The heat shrink tunnel shell has a channel length of 1500–2500mm, a width of 450mm, and a height of 200mm, meeting the space requirements for stacking multiple pieces. Anti-scalding baffles are installed at both ends of the channel to prevent burns to operators.

[0055] The circulating hot air system consists of two centrifugal fans, eight sets of stainless steel electric heating tubes, and four air nozzles on the top, bottom, left, and right sides. The air volume of the centrifugal fans is adjustable, the total power of the stainless steel electric heating tubes is 6–12kW, the temperature control range is 0–220℃, PID closed-loop control is adopted, the temperature fluctuation is ±2℃, and the hot air evenly covers the product surface to ensure uniform shrinkage of the film material without local overheating or insufficient shrinkage.

[0056] The conveyor chain is made of Teflon-coated stainless steel, which is resistant to high temperature, non-stick to film, and runs smoothly. The chain spacing is 50mm, and the load capacity is ≥5kg / ㎡. The chain speed is driven by a variable frequency motor and is steplessly adjustable from 0 to 15m / min. It can be flexibly set according to the specifications of the grinding wheel, the type of film material, and the number of stacked packages.

[0057] The temperature sensor is a Pt100 platinum resistance thermometer, used to collect the channel temperature in real time and feed it back to the PLC to adjust the heating power, ensuring the heat shrink process is stable and reliable.

[0058] In a preferred embodiment, the finished product discharge module (6) includes a discharge conveyor belt, a cooling air gun assembly, an air pressure regulating valve, a finished product collection frame, and a product counting sensor.

[0059] The discharge conveyor belt is a PVC green conveyor belt with a width of 500mm. Its speed is synchronized with that of the heat shrink chain plate. The thickness of the discharge conveyor belt is 3mm, and its surface is treated with anti-slip coating to ensure smooth product transition.

[0060] The cooling air gun assembly is equipped with 4 adjustable angle air guns, with compressed air pressure adjustable from 0.2 to 0.5 MPa, and is equipped with an air pressure regulating valve to quickly cool the heat-shrinked product, so that the film material can be quickly shaped and prevent rebound and wrinkling.

[0061] The finished product collection box is a stainless steel frame with an EVA cushioning pad inside to prevent products from falling and colliding and getting damaged. The collection box can hold 500 single pieces or 100 packs of multi-piece stacked products. The bottom of the finished product collection box is equipped with casters (642) for easy transportation.

[0062] The product counting sensor is a fiber optic sensor, used for accurate counting and capable of setting batch counting reminders, facilitating packing management.

[0063] In a preferred embodiment, the electrical control system (7) is a Siemens S7-1200 PLC, equipped with a 10-inch industrial touch screen, which has a user-friendly interface and is easy to operate; it also includes a power supply module, a relay module, and wiring terminals. The electrical control system (7) has the following functions:

[0064] Process parameter storage: It can store more than 20 sets of packaging parameters for different specifications of grinding wheels, which can be recalled with one click;

[0065] Automatic / Manual Mode Switching: Manual mode is used for debugging, and automatic mode is used for continuous production;

[0066] Real-time monitoring: Displays temperature, speed, count, operating status, and fault information;

[0067] Fault alarms: Automatic alarms and shutdowns for material shortage, material jamming, overheating, door opening, motor overload, etc.

[0068] Safety interlocks: Safety doors, emergency stop buttons, overload protection, and over-temperature protection provide comprehensive safety protection;

[0069] The electrical control system (7) is also equipped with standardized wiring for easy maintenance.

[0070] In a preferred embodiment, the pneumatic system (8) includes an air compressor interface, an oil-water separator, a pressure regulating valve, a solenoid valve, a cylinder, and a vacuum generator. It operates at a pressure of 0.4–0.6 MPa, has a fast response time, and operates stably without leakage. The air piping of the pneumatic system (8) is made of PU material, which is resistant to high pressure and corrosion. The piping is neatly arranged and clearly marked.

[0071] The working principle and full-process control of the fully automatic feeding, positioning, and heat shrink packaging machine for grinding wheels in this embodiment include:

[0072] After the equipment is started, the electrical control system (7) is initialized and each module is reset. The operator selects the grinding wheel specification on the touch screen (72), the system automatically calls the preset process parameters, the diameter adaptive adjustment mechanism (33) of the adaptive positioning module (3) drives the fixture to adjust to the corresponding diameter, and each module enters the standby state.

[0073] 1. Feeding process: Grinding wheels are stacked in the storage bin. The active roller and driven roller of the material distribution mechanism separate the stacked grinding wheels individually through the speed difference. The servo electric cylinder of the pushing mechanism drives the pushing plate to accurately push the single grinding wheel along the guide rail to the positioning platform. After the positioning detection sensor detects the grinding wheel, it sends a signal to the electrical control system (7), the pushing mechanism is reset, and the positioning action is triggered.

[0074] 2. Positioning process: The electronic control system (7) controls the stepper motor of the diameter adaptive adjustment mechanism to start, drives the three jaws to clamp the grinding wheel synchronously, and achieves centering; the angle detection photoelectric sensor detects the angle of the center mounting hole of the grinding wheel. If there is a deviation, the micro rotary cylinder drives the fixture to rotate slightly to correct it; after the correction is completed, the vacuum adsorption system starts, the vacuum generator generates negative pressure, and the grinding wheel is adsorbed and fixed through the adsorption hole. The positioning sensor detects the positioning accuracy. After passing the test, a signal is sent to the film sealing and cutting module (4) to enter the sealing and cutting process.

[0075] 3. Sealing and Cutting Process: The heat-shrinkable film on the film roll mounting bracket is conveyed by the film feeding servo mechanism. The tension adjustment roller maintains a constant tension of the film material, and the film material covers the positioned grinding wheel. The longitudinal sealing heating strip is activated to complete continuous heat sealing of the sides. After sealing, the conveying mechanism conveys the product forward to the transverse sealing station. The transverse sealing cutter is driven by the film cutting cylinder to complete the transverse sealing and cutting of the film material. The waste recycling mechanism simultaneously collects the sealing and cutting scraps. After sealing and cutting, the product enters the heat shrinking process.

[0076] 4. Heat shrinking process: The packaged product is conveyed to the conveyor chain of the adjustable speed heat shrinking module (5) and enters the heat shrinking channel with the chain. The centrifugal fan and electric heating tube of the circulating hot air system are started, and hot air is blown evenly to the product through the four-sided air nozzles. The film material shrinks evenly under the action of high temperature and fits tightly against the surface of the grinding wheel. The temperature sensor monitors the channel temperature in real time and adjusts the heating power through the PLC closed loop to ensure the heat shrinking temperature is stable. After heat shrinking is completed, the product is sent out of the heat shrinking channel with the chain and enters the discharge process.

[0077] 5. Discharge process: The heat-shrinked product enters the finished product discharge module (6), the cooling air gun group is started, and the product is quickly cooled and shaped by air; the shaped product is transported to the finished product collection box by the discharge conveyor belt; the product counting sensor counts the finished products, and the count is incremented by 1 for each product completed. When the preset batch quantity is reached, a reminder signal is issued; at the same time, the automatic feeding module (2) starts the feeding action of the next grinding wheel, enters the next cycle, and realizes continuous and uninterrupted automated production.

[0078] Application Example 1: Fully Automated Packaging of Single φ100mm×1.2mm Resin Cutting Sheets

[0079] The equipment used in this embodiment is the SL-R100 model, which is suitable for fully automatic packaging of single resin cutting discs with a diameter of φ100mm and a thickness of 1.2mm. Its power supply specification is AC380V. This 50Hz three-phase five-wire machine has a total power of 12kW and dimensions of 5200mm (L) × 1200mm (W) × 1600mm (H), weighing approximately 850kg. The adaptive clamp adjustment range is φ75–φ180mm, with a positioning repeatability of ±0.08mm. The heat shrink tunnel temperature is set at 160℃, with a constant temperature control accuracy of ±2℃. The conveyor chain speed is 8m / min. The packaging film is POF environmentally friendly heat shrink film, 0.05mm thick and 160mm wide. The longitudinal sealing temperature is set at 200℃, the transverse sealing temperature at 220℃, the sealing and cutting time is 0.3s, and the cooling air pressure is 0.3MPa. The machine has a production efficiency of 45–55 pieces / minute, a continuous operating time of ≥24 hours, a packaging qualification rate of ≥99.5%, a film utilization rate of ≥98%, and a changeover time of ≤3 minutes.

[0080] In actual production applications at a certain abrasive company, the equipment ran continuously for 72 hours without failure. Packaged products exhibited a smooth appearance, tight film adhesion, no misalignment or wrinkles, and stable positioning accuracy. Compared to manual packaging, efficiency was increased by 5 times, reducing the need for 4 packaging workers and saving approximately 200,000 yuan in labor costs annually. Film waste was reduced by 70%, demonstrating significant overall benefits. The equipment operated without material jamming or stacking, with a downtime rate of ≤0.5%. Operation was simple; ordinary workers could become proficient after just one hour of training.

[0081] Application Example 2: Stacking 5 high-power grinding discs (φ350mm×3.2mm)

[0082] The equipment used in this embodiment is the SL-M350 model, which is suitable for fully automatic packaging of single resin cutting discs with a diameter of φ350mm and a thickness of 3.2mm. Its power supply specification is AC380V. This 50Hz three-phase five-wire machine has a total power of 18kW and dimensions of 6200mm (L) × 1500mm (W) × 1800mm (H), weighing approximately 1100kg. The adaptive clamp adjustment range is φ200–φ400mm, with a positioning repeatability of ±0.12mm. The heat shrink tunnel temperature is set at 180℃, with a constant temperature control accuracy of ±2℃. The conveyor chain speed is 3.5m / min. The packaging film is high-strength PE heat shrink film, 0.10mm thick and 420mm wide. The longitudinal sealing temperature is set at 240℃, the transverse sealing temperature at 260℃, the sealing and cutting time is 0.5s, and the cooling air pressure is 0.4MPa. The machine has a production efficiency of 8-10 packs / minute, a continuous operating time of ≥24 hours, a packaging qualification rate of ≥99.2%, a film utilization rate of ≥97%, and a changeover time of ≤5 minutes.

[0083] The equipment parameters in Application Example 2 are suitable for large-size, thick, multi-piece stacking scenarios. The equipment ensures neat positioning, secure packaging, and prevents loosening or damage during transportation. After heat shrinking, the appearance is aesthetically pleasing and uniform. The equipment is highly compatible, allowing for rapid switching between any size within the φ200–φ400mm range to meet the needs of multi-variety production. In a large abrasive manufacturer, this equipment replaced 6 workers, increased single-shift output by 4 times, and reduced the packaging scrap rate from 5% in traditional processes to 0.8%, significantly lowering production costs and enhancing product market competitiveness.

[0084] This invention is applicable to various round abrasive products such as resin grinding wheels, cutting discs, angle grinding discs, diamond grinding discs, flap wheels, and polishing discs. It is widely used in abrasive manufacturing enterprises, hardware tool factories, building material processing enterprises, automated packaging production lines, and other scenarios. It can be used as a standalone machine or connected to upstream and downstream processes (such as grinding wheel production lines and finished product packing lines) to form a fully automated production line, adapting to the needs of large-scale and automated production.

[0085] Equipment installation requirements: The site must be flat with a ground load capacity of ≥1.5t / ㎡. Connect to AC380V 50Hz three-phase five-wire power supply (grounding resistance ≤4Ω), and connect to 0.4–0.6MPa dry compressed air. After leveling the equipment, fix the casters and it is ready for use. The installation is simple and convenient and does not require a professional installation team.

[0086] Routine maintenance includes:

[0087] 1. Daily maintenance: Clean the dust and film residue from the conveyor chain, positioning platform, and film sealing and cutting knife; check the air source pressure and oil pipe for leaks; check whether each sensor is working properly; clean the scraps on the waste recycling roller.

[0088] 2. Weekly maintenance: Lubricate the conveyor chain, lead screw, linear guide and other transmission components; check the wear of the heating tube and sealing knife; clean the dust and debris in the heat shrink channel; check whether the vacuum suction hole is blocked and clean it in time.

[0089] 3. Monthly maintenance: Check the operating status of the motor and fan, and clean the motor heat sink; check the aging of wires and air pipes, and replace damaged parts in time; calibrate the accuracy of temperature sensors and positioning sensors; check whether the safety protection devices are intact.

[0090] The main consumable parts of the equipment include polyurethane cushioning pads, sealing and cutting blades, heat shrink film, and conveyor belts. These consumable parts are easy to replace, require no special tools, have a long service life, and have low maintenance costs.

[0091] The equipment strictly complies with relevant national standards such as "General Rules for Design and Manufacture of Fixed and Movable Protective Devices for Mechanical Safety" (GB / T 8196-2018) and "Electrical Safety: Low-Voltage Electrical Installations" (GB / T 16895.1-2018), and has multiple safety protection functions, including:

[0092] 1. Safety door interlock: The equipment protective cover is equipped with maintenance safety doors on both sides, with limit switches. Opening the door will stop the machine to prevent operators from entering the danger zone while the equipment is running.

[0093] 2. Emergency stop protection: Emergency stop buttons are installed on both the front and side of the equipment. In case of emergency, pressing the emergency stop button will immediately cut off the power supply to the equipment and stop all operations.

[0094] 3. Over-temperature protection: When the temperature of the heat shrink tunnel exceeds the set upper limit (220℃), the electrical control system will automatically cut off the heating power and issue an alarm signal to prevent equipment damage and fire hazards.

[0095] 4. Overload protection: Each motor is equipped with an overload protection device. When the motor is overloaded, it will automatically stop and alarm to prevent the motor from burning out.

[0096] 5. Material shortage and jamming protection: When the storage bin is low on material, the equipment will issue an alarm signal and stop; when jamming occurs during feeding or conveying, the equipment will automatically stop to prevent the equipment from getting stuck and damaged.

[0097] 6. Scalding protection: Scalding baffles are installed at both ends of the heat shrink tunnel, and the protective cover is made of high temperature resistant acrylic material to prevent operators from being scalded.

[0098] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels, characterized in that, The system includes a frame assembly (1), an automatic feeding module (2), an adaptive positioning module (3), a film sealing and cutting module (4), an adjustable speed heat shrinking module (5), a finished product discharge module (6), and an electrical control system (7). The automatic feeding module (2), the adaptive positioning module (3), the film sealing and cutting module (4), the adjustable speed heat shrinking module (5), and the finished product discharge module (6) are installed sequentially on the frame assembly (1) along the conveying direction. The electrical control system (7) is electrically connected to each module to realize the coordinated operation of each module.

2. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, The adaptive positioning module (3) includes a positioning platform, a slotted three-jaw centering fixture, a diameter adaptive adjustment mechanism, an angle correction mechanism, and a vacuum adsorption unit; the surface of the positioning platform is uniformly distributed with vacuum adsorption holes, and the vacuum adsorption unit includes a vacuum generator and an adsorption pipeline.

3. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 2, characterized in that, The diameter adaptive adjustment mechanism consists of a stepper motor, a precision ball screw, a linear slider, and a synchronous transmission assembly. The stepper motor drives the precision ball screw to rotate, thereby causing the three-jaw chuck to synchronously extend and retract radially.

4. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 2, characterized in that, The three jaws of the slotted three-jaw centering fixture are evenly distributed at 120°, and each jaw is provided with a V-shaped slot. The inner wall of the slot is attached with a 3mm thick wear-resistant polyurethane buffer pad. The angle correction mechanism consists of a miniature rotary cylinder and an angle detection photoelectric sensor.

5. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, The adjustable speed heat shrink module (5) includes a double-layer heat shrink channel, a four-sided circulating hot air system, a Teflon conveyor chain, a frequency conversion speed control mechanism, and a temperature sensor; the heat shrink channel is made of double-layer 304 stainless steel, with 50mm thick high-temperature resistant aluminum silicate insulation cotton in the middle; the four-sided circulating hot air system consists of 2 centrifugal fans, 8 sets of stainless steel electric heating tubes, and four-sided air nozzles; the frequency conversion speed control mechanism is used to drive the conveyor chain in a stepless adjustment manner within the speed range of 0–15m / min.

6. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, The film sealing and cutting module (4) includes a film roll mounting bracket, a film feeding servo mechanism, a tension adjusting roller, a longitudinal sealing heating strip, a transverse sealing cutter, a film cutting cylinder, and a waste recycling mechanism; the film feeding servo mechanism is driven by a servo motor to feed a precision film feeding roller; the temperature of the longitudinal sealing heating strip is adjustable within the range of 0–300℃, and the width of the sealing edge is continuously adjustable within the range of 5–15mm; the transverse sealing cutter (45) is a high-temperature resistant alloy cutter, and the sealing and cutting time is adjustable within the range of 0.1–1s; a small roll roller is provided on the waste recycling mechanism for automatically recycling the sealing and cutting edge scraps.

7. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, The automatic feeding module (2) includes an inclined storage bin, a double-roller differential speed dispensing mechanism, a servo pushing mechanism, a guide rail, and a positioning detection sensor; the inclined storage bin has an inclination angle of 15° and width adjustment plates on both sides to accommodate grinding wheels with a thickness of 1.0–10 mm; the double-roller differential speed dispensing mechanism achieves single-sheet dispensing through the speed difference between the active roller and the driven roller; the servo pushing mechanism consists of a servo electric cylinder, a linear guide rail, and a polyurethane-coated pushing plate.

8. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, The finished product discharge module (6) includes a discharge conveyor belt, a cooling air gun assembly, an air pressure regulating valve, a finished product collection frame, and a product counting sensor; the cooling air gun assembly is equipped with 4 adjustable angle air guns, and the compressed air pressure is adjustable within the range of 0.2–0.5MPa; the finished product collection frame is lined with an EVA buffer pad; the product counting sensor is an optical fiber sensor, which can provide batch counting reminders.

9. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, The electrical control system (7) includes a PLC programmable logic controller and an industrial touch screen controller, and has the functions of process parameter storage, automatic / manual mode switching, real-time monitoring, fault alarm and safety interlock; the safety interlock function includes safety door limit switch, emergency stop button, overload protection and over-temperature protection.

10. The fully automatic feeding, positioning, and heat-shrink packaging machine for grinding wheels according to claim 1, characterized in that, It also includes a pneumatic system (8) and a safety protection system (9); the pneumatic system (8) includes an air compressor interface, an oil-water separator, a pressure regulating valve, a solenoid valve, a cylinder and a vacuum generator; the safety protection system (9) includes a high-strength aluminum alloy frame composite acrylic transparent protective cover, a maintenance safety door and a limit switch, wherein the machine stops when the maintenance safety door is opened.

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