A multi-group rope saw machine from wheel group device and control method

Abstract

This invention relates to a multi-set wire saw driven wheel assembly and control method, comprising a drive module and a driven wheel module. The driven wheel module includes a main shaft and multiple independently arranged driven wheel assemblies. Each driven wheel assembly includes a driven wheel component and a first bearing. The first bearing includes an inner ring and an outer ring. The drive module is connected to the main shaft. The driven wheel components are fixedly mounted on the outer ring, and the main shaft is fixedly mounted on the inner ring. The drive module drives the main shaft to rotate, and its rotation direction is consistent with that of the driven wheel components, thereby reducing the relative number of rotations between the inner and outer rings. Since the first bearing of the wire saw driven wheel assembly is inconvenient to disassemble and replace, this application sets up a drive module to drive the main shaft to rotate, and its rotation direction is consistent with that of the driven wheel components, thereby reducing the relative number of rotations between the inner and outer rings, thus reducing the wear of the first bearing and extending its service life. Furthermore, by controlling the rotational speed of the driven wheel components, the service life of the first bearing is further extended.

Description

Technical Field

[0001] This invention relates to the technical field of combined wire saws, and more particularly to a multi-group wire saw pulley assembly and control method. Background Technology

[0002] Wire saws are core equipment for cutting hard and brittle materials such as stone and concrete. Their driven wheel assembly, a key supporting component for the wire saw's transmission, typically consists of a fixed main shaft and multiple sets of independent driven wheels arranged sequentially along the main shaft's axis. Each set of driven wheels is assembled to the main shaft via a first bearing. During operation, the drive wheel propels the wire saw to high speed, while the wire saw, through friction, pulls each independent driven wheel to rotate around the main shaft, achieving tensioning, guiding, and auxiliary transmission of the wire saw, ensuring continuous cutting operations.

[0003] In the existing technology, the main shafts of multiple sets of driven wheel sets of wire saws are all designed to be fixed. The core purpose of this design is to simplify the assembly structure of the first bearing and reduce the difficulty of replacing the first bearing.

[0004] In the above-mentioned traditional structure, the disassembly and maintenance of the first bearing has an inherent drawback in terms of convenience. Since multiple driven wheels are arranged in series along the main shaft, when the first bearing inside the driven wheel located in the middle position is damaged and needs to be replaced, all driven wheels, end covers and related fasteners on the outside of the main shaft must be disassembled in sequence before the target bearing can be repaired or replaced. The whole process is time-consuming and laborious, which not only causes the wire saw machine to be shut down for a long time, but also increases the risk of decreased wheel assembly accuracy due to repeated disassembly and assembly.

[0005] In summary, the existing multiple sets of driven wheel sets of wire saws have extremely high requirements for service life due to the complicated disassembly and maintenance of the first bearing. However, the inherent design of the fixed main shaft causes the first bearing to rotate too many times relative to the main shaft under fluctuating speed conditions, resulting in excessive wear and aging, and thus failing to achieve the goal of long service life. Summary of the Invention

[0006] The first objective of this invention is to provide a multi-set drive assembly for a wire saw, which aims to solve the technical problem that the existing wire saw uses a fixed spindle design, resulting in a large number of relative rotations between the inner and outer rings of the bearings and easy wear.

[0007] To solve the above technical problems, a multi-set wire saw pulley assembly is provided, comprising:

[0008] Drive module;

[0009] The driven wheel module includes a main shaft and multiple independently arranged driven wheel assemblies. Each driven wheel assembly includes a driven wheel component and a first bearing. The first bearing includes an inner ring and an outer ring. The drive module is connected to the main shaft. The driven wheel component is fixedly installed on the outer ring, and the main shaft is fixedly installed on the inner ring. The drive module is used to drive the main shaft to rotate, and the rotation direction is consistent with that of the driven wheel component, so as to reduce the relative number of rotations between the inner ring and the outer ring.

[0010] Furthermore, the driven wheel module also includes a support base and a second bearing, the second bearing being mounted on the support base, and the main shaft being connected to the second bearing.

[0011] Furthermore, the driven wheel module also includes a water-cooling rotary joint, which is rotatably arranged relative to the main shaft, and the driven wheel module is connected to an external cooling water supply system through the water-cooling rotary joint.

[0012] Furthermore, the drive module includes a drive motor, a first pulley, a second pulley, and a transmission belt. The first pulley is mounted on the drive motor, the second pulley is mounted on the main shaft, and the transmission belt is coupled between the first pulley and the second pulley.

[0013] Furthermore, the plurality of driven wheel assemblies are spaced apart along the axial direction of the main shaft.

[0014] The second objective of this invention is to provide a control method for the aforementioned multi-set wire saw driven wheel assembly, wherein the multi-set wire saw driven wheel assembly further includes a controller and a data acquisition unit. The data acquisition unit includes a speed sensor, a wire saw tension sensor, a bearing temperature sensor, and a dust concentration sensor, all electrically connected to the controller. The speed sensor is used to acquire the real-time speed of the driven wheel, the tension sensor is used to acquire the real-time tension of the wire saw, the bearing temperature sensor is used to acquire the real-time temperature of the first bearing, and the dust concentration sensor is used to acquire the ambient dust concentration.

[0015] Furthermore, the controller has a built-in speed calculation model. The speed calculation model uses the arithmetic mean of the real-time speeds of all driven wheels as a benchmark, and calculates the target speed of the spindle by coupling the working condition corrections of wire saw tension, bearing average temperature, and ambient dust concentration. The drive module then dynamically adjusts the spindle speed according to the target spindle speed.

[0016] Furthermore, the formula for calculating the target spindle speed is as follows: ;

[0017] in, The target spindle speed. The arithmetic mean of the real-time rotational speeds of all driven gears. This is the correction amount for the wire saw tension. This is the temperature correction amount for the first bearing. This is the correction amount for dust concentration.

[0018] Furthermore, ;in, The number of the driven wheel assemblies. For the first The real-time rotational speed of the driven wheel component;

[0019] ;in, This is the wire saw tension weighting coefficient. For wire saw tension correction factor, For real-time wire saw tension, The rated working tension for the wire saw;

[0020] ;in, The first bearing temperature weighting coefficient. This is the first bearing temperature correction factor. The real-time average temperature of all first bearings. The rated operating temperature of the first bearing;

[0021] ;in, This is the dust concentration weighting coefficient. This is a dust concentration correction factor. This represents the real-time ambient dust concentration. The dust concentration threshold is, and .

[0022] Furthermore, the multi-set wire saw machine pulley assembly also includes a flow control valve, which is located at the water inlet end of the water-conducting rotary joint. When the real-time average temperature of the first bearing exceeds a preset warning value, the controller synchronously sends a control command to adjust the spindle speed through the drive module to reduce relative rotation, and controls the flow control valve to increase the cooling water flow rate. The flow control valve increases the cooling water flow rate to 1.2-1.5 times the base flow rate.

[0023] Implementing the embodiments of the present invention will have the following beneficial effects:

[0024] In this embodiment of the multi-set wire saw driven wheel assembly, since the first bearing of the driven wheel assembly is inconvenient to disassemble and replace, this application sets up a drive module to drive the main shaft to rotate. The rotation direction of the main shaft is consistent with the rotation direction of the driven wheels, so as to reduce the relative number of rotations between the inner and outer rings of the first bearing, thereby reducing the wear of the first bearing and extending its service life. This solution dynamically adjusts the speed of the main shaft through a controller, combined with a multi-sensor fusion algorithm, using the average real-time speed of all driven wheels as a benchmark, and superimposing corrections for tension, temperature, and dust conditions, to minimize the variance between the main shaft speed and the driven wheel speed, thereby reducing the relative number of rotations between the inner and outer rings of the first bearing to a minimum, further extending the service life of the first bearing. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of a multi-set wire saw wheel assembly device including a wire saw and a driven wheel, as described in an embodiment of the present invention.

[0027] Figure 2 This is a schematic diagram of the structure of the multi-group wire saw shear assembly device according to an embodiment of the present invention;

[0028] Figure 3 This is a cross-sectional view of the multi-wire saw machine with a wheel assembly as described in an embodiment of the present invention;

[0029] Figure 4 This is a schematic diagram of the driven wheel assembly according to an embodiment of the present invention;

[0030] Figure 5 This is a control principle diagram of the multi-group wire saw machine slave wheel assembly device according to an embodiment of the present invention.

[0031] The components include: 100, multiple sets of wire saw driven pulley assembly; 110, drive module; 111, drive motor; 112, first pulley; 113, second pulley; 114, transmission belt; 120, driven pulley module; 121, main shaft; 1211, cooling channel; 122, driven pulley assembly; 1221, driven pulley component; 1222, first bearing; 1222A, inner ring; 1222B, outer ring; 1223, support base; 1224, second bearing; 1225, water-conducting rotary joint; 130, controller; 140, acquisition unit; 141, wire saw tension sensor; 142, bearing temperature sensor; 143, dust concentration sensor; 144, speed sensor; 150, drive pulley; 160, wire saw. Detailed Implementation

[0032] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0033] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0035] Please refer to Figures 1-5This invention provides a multi-set wire saw driven wheel assembly 100, which includes a drive module 110 and a driven wheel module 120. The driven wheel module 120 includes a main shaft 121 and multiple independently arranged driven wheel assemblies 122. Each driven wheel assembly 122 includes a driven wheel component 1221 and a first bearing 1222. The first bearing includes an inner ring 1222A and an outer ring 1222B. The drive module 110 is connected to the main shaft 121. The driven wheel component 1221 is fixedly mounted on the outer ring 1222B, and the main shaft 121 is fixedly mounted on the inner ring 1222A. The drive module 110 drives the main shaft 121 to rotate in the same direction as the rotation of the driven wheel component 1221, thereby reducing the relative number of rotations between the inner ring 1222A and the outer ring 1222B. For example, the driven wheel module 120 cooperates with the wire saw 160 through multiple independent driven wheel assemblies 122 arranged axially along the main shaft 121. It receives power from the drive wheel 150 driving the wire saw 160, guides the wire saw 160 to run along a preset trajectory, and provides continuous tension to the wire saw 160, preventing slippage and deviation during high-speed cutting, thus ensuring the stability of the wire saw 160's transmission and the accuracy of the cutting trajectory. The first bearing 1222 is a thin bearing. It is understood that if the main shaft 121 were a fixed design, the rotation of the driven wheel assembly 1221 would cause wear to the first bearing 1222. Therefore, this application sets the main shaft 121 to rotate in the same direction as the driven wheel assembly 1221, thereby reducing the relative number of rotations between the inner ring 1222A and the outer ring 1222B, reducing the wear of the first bearing 1222, and thus extending the service life of the first bearing 1222.

[0036] In this embodiment, the multi-set wire saw driven wheel assembly 100 addresses the inconvenience of disassembling and replacing the first bearing 1222 of the wire saw driven wheel assembly. Therefore, this application sets up a drive module 110 to drive the main shaft 121 to rotate. The rotation direction of the main shaft 121 is consistent with the rotation direction of the driven wheel 1221, thereby reducing the relative rotation number between the inner ring 1222A and the outer ring 1222B, thus reducing the wear of the first bearing 1222 and extending its service life. This solution dynamically adjusts the speed of the main shaft 121 through the controller 130, and combines a multi-sensor fusion algorithm, using the average real-time speed of all driven wheel 1221 as a benchmark, and superimposing tension, temperature, and dust condition corrections, to minimize the variance between the speed of the main shaft 121 and the speed of the driven wheel 1221. This further reduces the relative rotation number between the inner ring 1222A and the outer ring 1222B of the first bearing 1222 to a minimum, thereby further extending the service life of the first bearing 1222. Minimizing variance means that the variance between the rotational speed of the main shaft 121 and the rotational speeds of all driven wheels 1221 is ≤0.5 r² / min².

[0037] Please refer to Figure 2 , Figure 3 and Figure 4 In one possible implementation, the driven wheel module 120 further includes a support base 1223 and a second bearing 1224. The second bearing 1224 is mounted on the support base 1223, and the main shaft 121 is connected to the second bearing 1224. Exemplarily, two support bases 1223 and two bearings 1224 are provided, with one second bearing 1224 mounted on each support base 1223. It can be understood that each support base 1223 and each second bearing 1224 constitute a group, with the two groups respectively mounted at both ends of the main shaft 121. It should be noted that since the driven wheel module 120 consists of multiple groups of spaced-apart driven wheel assemblies 122, and the gap between adjacent driven wheel assemblies 122 is very small, the second bearing 1224 is easier to disassemble than the first bearing 1222. Although rotation of the main shaft 121 will also cause wear on the second bearing 1224, it is obviously much easier to replace and maintain than the difficult-to-disassemble first bearing 1222. Furthermore, since the internal space of the driven wheel module 120 is limited, the first bearing 1222 is small and thin, and its theoretical life is short. However, the space outside the driven wheel module 120 is not limited, so the second bearing 1224 is large and thick, and its theoretical life is long. This is equivalent to transferring the wear on the first bearing 1222 to the external second bearing 1224, which is easy to replace.

[0038] Please refer to Figure 2 and Figure 3In one possible implementation, the driven wheel module 120 further includes a water-cooling rotary joint 1225, which is rotatably disposed relative to the main shaft 121. The driven wheel module 120 is connected to an external cooling water supply system through the water-cooling rotary joint 1225. Exemplarily, the main shaft 121 includes a cooling channel 1211, which is a through hole extending axially along the main shaft 121. The external cooling water supply system communicates with the cooling channel 1211 through the water-cooling rotary joint 1225. It is understood that the cooling channel 1211 is a through hole axially formed in the main shaft 121, through which cooling water circulates within the main shaft 121, transferring heat away through heat transfer between the main shaft 121 and the cooling water. A sealing structure is provided at the connection point between the outer ring 1222B water-cooling rotary joint 1225 and the main shaft 121. This sealing structure ensures that the water-cooling rotary joint 1225 rotates relative to the main shaft 121 while maintaining a tight seal. The water rotary joint comprises a moving body and a stationary body. The moving body is threaded to the end of the main shaft 121, and the stationary body is flanged to the external cooling water pipeline. A sealing structure is provided between the moving and stationary bodies, consisting of a combination of double-layer graphite sealing rings and fluororubber O-rings. Because the first bearing 1222 is extremely difficult to disassemble and maintain, its high-temperature tolerance is extremely low. The water rotary joint 1225 can maintain continuous and sealed cooling water passages under dynamic conditions of high-speed rotation of the main shaft 121. In this design, the main shaft 121 is driven by a servo motor and is in a continuous, dynamic, adaptive rotation state, while the external cooling water pipeline is fixed. The water rotary joint 1225, through its special structure of connecting the pipeline to the stationary body and the main shaft 121 to the moving body, achieves seamless connection between the fixed and rotating flow channels. This prevents water pipe entanglement or breakage due to the rotation of the main shaft 121, and also eliminates leakage and water outages. The cooling effect of the water-cooled rotary joint 1225 can maintain the thermal balance between the spindle 121 and the driven wheel, prevent the spindle 121 from jumping or the driven wheel from jamming due to thermal deformation, ensure the accuracy of the data collected by the speed sensor 144, ensure the smooth execution of the speed regulation logic with minimum variance, and indirectly improve the cutting accuracy of the whole machine.

[0039] Please refer to Figure 2 In one possible implementation, the drive module 110 includes a drive motor 111, a first pulley 112, a second pulley 113, and a transmission belt 114. The first pulley 112 is mounted on the drive motor 111, the second pulley 113 is mounted on the main shaft 121, and the transmission belt 114 is coupled between the first pulley 112 and the second pulley 113. Exemplarily, the first pulley 112 and the second pulley 113 are synchronous pulleys, and the transmission belt 114 is a synchronous belt. In this embodiment, the drive motor 111 is an AC permanent magnet synchronous servo motor.

[0040] Please refer to Figure 2 , Figure 3 and Figure 4 In one possible implementation, multiple driven wheel assemblies 122 are spaced apart along the axial direction of the main shaft 121. Exemplarily, the multiple driven wheel assemblies 122 are arranged at equal intervals along the axial direction of the main shaft 121, with an installation gap between adjacent driven wheel assemblies 122 to accommodate the working conditions of the wire saw. This gap size can be adjusted according to the arrangement spacing of the wire saw 160 and the actual needs of the cutting operation. Furthermore, the central axis of each driven wheel assembly 122 is collinear with the central axis of the main shaft 121, ensuring coaxiality of each driven wheel assembly 122 as it rotates with the main shaft 121.

[0041] Please refer to Figure 5In one possible implementation, the multi-set wire saw driven wheel assembly 100 further includes a controller 130 and a data acquisition unit 140. The data acquisition unit 140 includes a speed sensor 144, a wire saw tension sensor 141, a bearing temperature sensor 142, and a dust concentration sensor 143, all electrically connected to the controller 130. The speed sensor 144 is used to acquire the real-time speed of the driven wheel 1221, the tension sensor is used to acquire the real-time tension of the wire saw 160, the bearing temperature sensor 142 is used to acquire the real-time temperature of the first bearing 1222, and the dust concentration sensor 143 is used to acquire the ambient dust concentration. Exemplarily, the controller 130 is preferably an embedded industrial computer or a programmable logic controller 130, integrated into a protective housing next to the support base 1223 of the driven wheel assembly. Its core function is to receive real-time data from the data acquisition unit 140, run an adaptive speed algorithm for the spindle 121, and send speed control commands to the drive motor 111. The acquisition unit 140, serving as the core of the working condition sensing, is electrically connected to the controller 130 via a shielded cable, possessing anti-interference and vibration-resistant transmission characteristics. The tension sensor 141 for the wire saw 160 employs a tension / compression sensor or a tension wheel sensor, specifically positioned on the outer side of the tangential contact section between each wire saw 160 and the corresponding driven wheel 1221. The bearing temperature sensor 142 employs a high-temperature resistant thermistor sensor or a patch-type temperature sensor, specifically embedded inside the wheel body of each driven wheel assembly 122, and attached to the outer ring 1222B end face of the first bearing 1222. The dust concentration sensor 143 employs a laser scattering dust sensor, specifically fixed to the top of the support base 1223 of the driven wheel assembly, located directly above the central axis of multiple driven wheel assemblies 122, 15-20 cm from the working plane of the driven wheel assembly. The speed sensor 144 is a magnetoelectric speed sensor 144, and each driven wheel assembly 122 is provided with a speed sensor 144. Specifically, the speed sensor 144 is installed on the driven wheel component 1221. The speed sensor 144 is embedded in the non-working end face of the driven wheel component 1221, and three rare earth magnet induction blocks are evenly arranged around the center of the driven wheel component 1221 with a spacing of 120°. The radial distance between the sensor detection end and the induction block is 3-5mm. The sensor is covered with a waterproof and dustproof metal protective cover, which is fixed by anti-loosening bolts, and the lead wire is led out through a waterproof connector.

[0042] In one possible implementation, the controller 130 has a built-in speed calculation model. The speed calculation model is based on the arithmetic mean of the real-time speeds of all driven wheel components 1221. It is coupled with the working condition corrections of the wire saw tension, bearing average temperature, and ambient dust concentration to obtain the target speed of the spindle 121. The drive module 110 performs dynamic adjustment of the spindle 121 speed according to the target speed of the spindle 121.

[0043] In one possible implementation, the formula for calculating the target rotational speed of the spindle 121 is: ;

[0044] in, The target rotational speed of spindle 121 The arithmetic mean of the real-time rotational speeds of all driven gears 1221. For the tension correction of the wire saw 160, This is the temperature correction amount for the first bearing 1222. This is the correction amount for dust concentration.

[0045] In one possible implementation, ;in, The number of driven wheel assemblies 122 For the first The real-time rotational speed of the driven wheel assembly 1221 is monitored; a magnetoelectric speed sensor 144 is installed on the end face of each driven wheel assembly 1221 to collect the real-time rotational speed of the driven wheel assembly 1221. The sampling frequency is 50Hz.

[0046] ;in, For the wire saw 160 tension weighting coefficient, For the tension correction factor of wire saw 160, For real-time wire saw tension of 160, The rated working tension for the wire saw 160; in this embodiment, The value range is set to 1000-1500N. Set to 0.02r / (min·N).

[0047] ;in, The temperature weighting coefficient for the first bearing 1222. For the temperature correction factor of the first bearing 1222, The real-time average temperature of all first bearings 1222 The rated operating temperature of the first bearing 1222; in this embodiment, The value range is 60-70℃. Set to 0.1 r / (min·℃).

[0048] ;in, This is the dust concentration weighting coefficient. This is a dust concentration correction factor. This represents the real-time ambient dust concentration. The dust concentration threshold is, and In this embodiment, The dust concentration threshold is set to 50 mg / m³. The correction factor is set to 0.01 r / (min・mg / m³). The correction factor is calibrated through a wire saw bench test. Specifically, under rated load, the tension of the wire saw 160, bearing temperature, and dust concentration are changed, and the change in the driven wheel speed is recorded. The correction factor value is obtained through linear fitting. The correction factor in this embodiment is applicable to the conventional working conditions of a 11.5mm diameter diamond wire saw 160 cutting hard and brittle materials such as granite and concrete. If the wire saw 160 model / material is changed, it can be recalibrated through a bench test. The variance threshold between the spindle speed 121 and the driven wheel speed 1221 is ≤0.5 r² / min². When the variance exceeds this threshold, the controller 130 fine-tunes the spindle speed 121 through the drive module 110. The spindle speed adjustment accuracy of the drive motor 111 is ±1 r / min, ensuring that the variance quickly drops below the threshold.

[0049] The above formula is not a simple mathematical calculation, but an engineering-based quantitative mapping of the actual cutting conditions of the wire saw machine, where the wire saw tension weighting coefficient is 160. Temperature weighting coefficient of the first bearing 1222 Environmental dust concentration weighting coefficient As three core compensation coefficients, these are key design features for translating optimal mathematical calculations into optimal engineering applications. Their design is essentially to ensure that the spindle speed adjustment of the main shaft 121 precisely matches the actual operating characteristics of the wire saw, and to address the core invention objective of maximizing the service life of the first bearing 1222 due to its inconvenient disassembly. In cutting hard and brittle materials such as stone and concrete, the three operating parameters—wire saw tension 160, first bearing 1222 temperature, and ambient dust concentration—directly affect the rotational stability of the driven wheel and the degree of friction and wear on the first bearing 1222. Furthermore, the priority and intensity of each parameter's impact on bearing protection vary significantly. For example, when cutting hard burrs, the impact of a sudden change in wire saw tension 160 is far greater than a slight change in dust concentration, and when the temperature of the first bearing 1222 approaches the warning value, the temperature's impact becomes paramount. If the target speed of the spindle 121 is simply calculated by superimposing the three working condition corrections without differentiating the intensity of each correction, the speed regulation will deviate from the actual working condition requirements. This can lead to minor issues such as insufficient speed matching between the spindle 121 and the driven wheel, resulting in the first bearing 1222 rotating an extra number of relative revolutions; or more serious issues such as bearing overheating and seizure, and dust and abrasive wear, due to neglecting the influence of higher-priority working conditions. Therefore, setting... , , The core purpose of the three compensation coefficients is to differentiate the weight allocation of the correction effects of the three major working condition parameters, so that the speed calculation model can highlight the adjustment effect of the core influencing factors and weaken the interference of secondary factors according to the actual working conditions. This ensures that the final calculated target speed of the main shaft 121 not only meets the basic requirement of minimizing the variance between the driven wheel speed and the main shaft 121 speed, but also achieves targeted protection for the first bearing 1222, making the formula calculation results truly suitable for actual engineering applications.

[0050] All three compensation coefficients are dimensionless coefficients between 0 and 1, and satisfy the following conditions: The constraint relationship ensures that the overall speed correction range is controllable, preventing excessive speed adjustment of the spindle 121 due to the superposition of multiple corrections, which could lead to transmission synchronization loss. It also enables dynamic adaptation of various coefficients. When the influence priority of a certain operating parameter is increased, its corresponding compensation coefficient can be increased accordingly, while the other coefficients decrease synchronously. This eliminates the need to change the basic calibration value of the correction factor, resulting in stronger adaptability.

[0051] Wire saw 160 tension weighting factor This is used to quantify the effect of tension changes in the wire saw 160 on the speed regulation of the spindle 121. The tension of the wire saw 160 is the core factor determining the fluctuation of the driven wheel's speed; sudden tension changes directly lead to a sharp change in the driven wheel's speed, thereby increasing the relative rotational number of revolutions between the first bearing 1222 and the spindle 121. Therefore, under normal cutting conditions... As the fundamental core coefficient among the three coefficients, it has the highest weighting and is usually calibrated to 0.4-0.5. This ensures that when the tension of the wire saw 160 changes, the spindle speed 121 can make targeted and significant adjustments, quickly offsetting the speed deviation caused by tension and reducing additional wear on the bearings from the root.

[0052] Temperature weighting coefficient of first bearing 1222 This is used to quantify the effect of temperature changes in the first bearing 1222 on the speed regulation of the spindle 121. Temperature is a direct factor affecting the service life of the first bearing 1222. When the bearing temperature rises, the lubrication efficiency of the lubricating medium decreases rapidly. Even a small relative rotation can cause severe wear on the bearing, and this effect is more significant the closer the temperature is to the warning value. Therefore... The core protection coefficient has adjustable priority. Under normal operating conditions, the weight allocation ratio is moderate, usually calibrated to 0.3-0.4. When the bearing temperature approaches the preset warning value, the weight ratio can be dynamically increased through the controller 130, so that the speed adjustment is tilted towards reducing the relative rotation of the bearing and suppressing frictional heat generation, thereby achieving high temperature protection for the bearing.

[0053] Environmental dust concentration weighting coefficient This is used to quantify the effect of changes in environmental dust concentration on the speed regulation of the spindle 121. Dust can intrude into the sealing gap of the first bearing 1222, causing abrasive wear and increasing the bearing's frictional resistance. This leads to increased fluctuations in the driven wheel's speed, and the higher the dust concentration, the greater the frictional resistance and wear. However, the effect of dust on speed is a gradual and indirect one. Compared to the immediate effects of sudden tension changes or rapid temperature rises, its effect is slower. Therefore, under normal operating conditions... The weight allocation is the lowest, usually calibrated to 0.1-0.2, mainly used for minor corrections to dust conditions, to avoid the accumulation of speed deviation caused by increased frictional resistance, and to prevent the transmission stability of the spindle 121 from decreasing due to frequent minor adjustments.

[0054] It needs to be clarified that the three compensation coefficients , , With the corresponding correction factor , , It represents a coordinated relationship, not an independent action. The compensation coefficient is a weighting coefficient that can be dynamically adjusted according to the operating conditions. It is used to differentiate and amplify or reduce the converted speed correction amount, solving the problem of different influence intensities under different operating conditions.

[0055] For the high-load conditions of stone cutting, it can be Adjust to 0.5 Adjust to 0.3 Adjust to 0.2 to highlight the core role of tension regulation; for high-dust conditions during concrete cutting, it can be... Adjust to 0.3 Adjust to 0.4 Adjust to 0.3 to enhance the correction effect under dust conditions; when the temperature of the first bearing 1222 approaches the warning value, it can be temporarily adjusted. Adjust to 0.5 to prioritize high-temperature protection of the bearing.

[0056] This application introduces three compensation coefficients to... Based on the fundamental benchmark, ensure the overall matching degree between the spindle speed 121 and the driven wheel speed, and achieve the basic requirement of minimizing variance; with , , The working condition correction factor incorporates key influencing factors in actual cutting into the calculation, ensuring that the speed adjustment closely matches the actual engineering situation; , , To compensate for the differential distribution of the impact intensity under various operating conditions, the speed regulation is always guided by the goal of extending the service life of the first bearing 1222. Simultaneously, the constraint relationship between the three compensation coefficients is also considered. This ensures that the adjustment range of the spindle speed 121 is always within a safe range, avoiding secondary problems such as loss of synchronization between the spindle 121 and the driven wheel, and slippage of the wire saw 160 due to excessive adjustment, while taking into account both bearing protection and the overall transmission stability of the equipment.

[0057] The dynamic adjustment rules for weighting coefficients include: under normal operating conditions, =0.45, =0.35, =0.2. When the temperature of the first bearing 1222 is ≥65℃, it will Adjust to 0.3 Adjust to 0.5 Adjust to 0.2, reset when temperature ≤ 60℃. When dust concentration ≥ 80mg / m³, Adjust to 0.4 Adjust to 0.3 Reset when the concentration is ≤50mg / m³ and adjusted to 0.3. When the tension of the wire saw (160mm) is ≥1800N, [the following applies]. Adjust to 0.55 Adjust to 0.3 Reset when adjusted to 0.15 and tension ≤ 1500N.

[0058] In one possible implementation, the multi-set wire saw driven wheel assembly 100 also includes a flow control valve (not shown in the figure), which is located at the water inlet of the water-passing rotary joint 1225. When the real-time average temperature of the first bearing 1222 exceeds a preset warning value, the controller 130 synchronously sends a control command to adjust the rotation speed of the main shaft 121 through the drive module 110 to reduce relative rotation, and controls the flow control valve to increase the cooling water flow. For example, the flow control valve is preferably an electromagnetic proportional flow valve, which features fast response and high flow regulation accuracy. Specifically, the flow control valve is connected in series on the water inlet pipe of the water-passing rotary joint 1225, with one end connected to the external cooling water supply system via a high-pressure hose, and the other end connected to the stationary water inlet of the water-passing rotary joint 1225 via a threaded seal. The advantage of this installation position is that it can directly control the total flow rate of cooling water entering the driven wheel assembly, ensuring that the flow regulation command can act on the entire cooling channel in real time, while avoiding interference with the working state of the flow control valve due to the rotation of the main shaft 121.

[0059] During the operation of the device in this application, the flow control valve does not always maintain a fixed flow output. Instead, under the unified scheduling of the controller 130, it forms a dynamic control logic that is synchronized and coordinated with the drive module 110 based on the real-time temperature conditions of the first bearing 1222. The specific working process is as follows:

[0060] The controller 130 acquires the temperature data of the first bearing 1222 in all driven wheel assemblies 122 in real time through the bearing temperature sensor 142 in the acquisition unit 140, and calculates the real-time average temperature of the first bearing 1222 through an algorithm. The controller 130 has a pre-stored temperature warning value for the first bearing 1222, which is usually set to 60℃-70℃. When the real-time average temperature of the first bearing 1222 is detected to be below the preset warning value, the flow control valve maintains the preset basic working flow rate, and the water rotary joint 1225 delivers cooling water to the internal flow channel of the main shaft 121 at a constant flow rate to meet the heat dissipation requirements of the driven wheel assembly under normal operating conditions. At this time, the drive module 110 only makes normal fine adjustments to the speed of the main shaft 121 based on the fluctuation of the driven wheel speed and tension and dust conditions.

[0061] When the real-time average temperature of the first bearing 1222 exceeds the preset warning value, it indicates that the first bearing 1222 is at risk of abnormal temperature rise due to increased instantaneous load, accumulated relative rotation revolutions, or decreased lubrication efficiency. At this time, the controller 130 immediately activates the collaborative protection program, simultaneously sending two control commands to achieve simultaneous execution of active friction reduction and enhanced heat dissipation: The first command is sent to the drive module 110, which further precisely fine-tunes the spindle speed 121 through the drive motor 111. By optimizing the speed matching, the relative rotation revolutions between the first bearing 1222 and the spindle 121 are minimized, reducing the source of frictional heat generation at its root. The second command is simultaneously sent to the flow control valve, which controls the valve core opening of the electromagnetic proportional flow valve to increase the supply flow of cooling water according to a preset ratio, which is usually 1.2-1.5 times the base flow. The increased cooling water flow is continuously delivered to the cooling channel inside the spindle 121 through the water-passing rotary joint 1225, significantly improving heat exchange efficiency, accelerating the removal of heat accumulated in the first bearing 1222, and suppressing the continuous rise in temperature. Through the above-mentioned collaborative control logic, the flow control valve and the drive module 110 form a complementary and linked protection effect. The drive module 110 actively intervenes from the perspective of reducing heat generation, while the flow control valve passively strengthens from the perspective of accelerating heat dissipation. The combination of the two can reduce the temperature of the first bearing 1222 to a safe range in a very short time, effectively avoiding failures such as carbonization of lubricating medium and bearing jamming caused by high temperature.

[0062] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A multi-set wire saw pulley assembly, characterized in that, include: Drive module; The driven wheel module includes a main shaft and multiple independently arranged driven wheel assemblies. Each driven wheel assembly includes a driven wheel component and a first bearing. The first bearing includes an inner ring and an outer ring. The drive module is connected to the main shaft. The driven wheel component is fixedly installed on the outer ring, and the main shaft is fixedly installed on the inner ring. The drive module is used to drive the main shaft to rotate, and the rotation direction is consistent with that of the driven wheel component, so as to reduce the relative number of rotations between the inner ring and the outer ring.

2. The multi-set wire saw pulley assembly according to claim 1, characterized in that, The driven wheel module also includes a support base and a second bearing, the second bearing being mounted on the support base, and the main shaft being connected to the second bearing.

3. The multi-set wire saw pulley assembly according to claim 2, characterized in that, The driven wheel module also includes a water-cooling rotary joint, which is rotatably arranged relative to the main shaft. The driven wheel module is connected to an external cooling water supply system through the water-cooling rotary joint.

4. The multi-set wire saw pulley assembly according to claim 1, characterized in that, The drive module includes a drive motor, a first pulley, a second pulley, and a transmission belt. The first pulley is mounted on the drive motor, the second pulley is mounted on the main shaft, and the transmission belt is coupled between the first pulley and the second pulley.

5. The multi-set wire saw pulley assembly according to claim 1, characterized in that, The plurality of driven wheel assemblies are spaced apart along the axial direction of the main shaft.

6. A control method for the multi-set wire saw driven sheave assembly, used to implement the multi-set wire saw driven sheave assembly as described in any one of claims 1-5, characterized in that, The multi-set wire saw driven wheel assembly also includes a controller and a data acquisition unit. The data acquisition unit includes a speed sensor, a wire saw tension sensor, a bearing temperature sensor, and a dust concentration sensor, all electrically connected to the controller. The speed sensor is used to acquire the real-time speed of the driven wheel, the tension sensor is used to acquire the real-time tension of the wire saw, the bearing temperature sensor is used to acquire the real-time temperature of the first bearing, and the dust concentration sensor is used to acquire the ambient dust concentration.

7. The control method for the multi-group wire saw machine drive assembly according to claim 6, characterized in that, The controller has a built-in speed calculation model. The speed calculation model is based on the arithmetic mean of the real-time speeds of all driven wheels. It calculates the target speed of the spindle by coupling the working condition corrections of wire saw tension, bearing average temperature, and ambient dust concentration. The drive module performs dynamic adjustment of the spindle speed according to the target spindle speed.

8. The control method for the multi-group wire saw machine drive assembly according to claim 7, characterized in that, The formula for calculating the target spindle speed is: ; in, The target spindle speed. The arithmetic mean of the real-time rotational speeds of all driven gears. This is the correction amount for the wire saw tension. This is the temperature correction amount for the first bearing. This is the correction amount for dust concentration.

9. The control method for the multi-group wire saw machine drive assembly according to claim 8, characterized in that, ;in, The number of the driven wheel assemblies. For the first The real-time rotational speed of the driven wheel component; ;in, This is the wire saw tension weighting coefficient. For wire saw tension correction factor, For real-time wire saw tension, The rated working tension for the wire saw; ;in, The first bearing temperature weighting coefficient. This is the first bearing temperature correction factor. The real-time average temperature of all first bearings. The rated operating temperature of the first bearing; ;in, This is the dust concentration weighting coefficient. This is a dust concentration correction factor. This represents the real-time ambient dust concentration. The dust concentration threshold is, and .

10. The control method for the multi-group wire saw machine drive assembly according to claim 9, characterized in that, The multi-group wire saw drive assembly also includes a flow control valve, which is located at the water inlet of the water-conducting rotary joint. When the real-time average temperature of the first bearing exceeds a preset warning value, the controller synchronously sends a control command to adjust the spindle speed through the drive module to reduce relative rotation, and controls the flow control valve to increase the cooling water flow rate. The flow control valve increases the cooling water flow rate to 1.2-1.5 times the base flow rate.

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