A spiral string of beads, a string of beads and a manufacturing apparatus and method thereof

Abstract

The application discloses a spiral string bead, a string bead rope and a manufacturing device and method thereof, and the manufacturing device comprises a continuous feeding assembly, a feeding coating assembly, a grinding particle coating assembly and a mold loading assembly, and can realize continuous transfer of a string bead base, uniform coating of a bonding agent, quantitative coating of grinding particles and automatic mold loading, so that automatic preparation of the grinding particle string bead is realized. The grinding particle string bead provided by the application has a spiral coiled abrasive body structure on the outer surface, and a chip removal channel is formed between adjacent abrasive body structures, so that a functional structure in which grinding areas and chip removal channels are alternately distributed is constructed on the surface of the string bead, so that the chip removal condition and machining stability in the cutting process are improved. The grinding particles and the string bead base form a metallurgical bond, and the bonding strength is high, so the grinding particles are not easy to fall off. The string bead rope obtained by the application has excellent sharpness, wear resistance and service life, and the cutting seam is neat, and is suitable for efficient and high-precision cutting processing of hard and brittle materials.

Description

Technical Field

[0001] This invention belongs to the field of abrasive tool manufacturing and precision machining technology, and relates to an abrasive bead and its bead rope structure, as well as an automated production equipment and manufacturing method for preparing the abrasive bead. In particular, it relates to an abrasive bead, bead rope and its preparation equipment and method for realizing the spiral orderly arrangement of abrasive grains along the surface of a substrate. The abrasive bead can be applied to the field of high-precision material cutting and processing, including but not limited to the processing of hard and brittle materials and semiconductor materials. Background Technology

[0002] Abrasive beaded wire is a tool used for material cutting and processing. Initially, it was mainly used in construction, mining, and infrastructure development, playing a role in stone cutting and structural demolition. However, these applications had relatively low requirements for processing precision and consistency. With the development of advanced manufacturing technologies, abrasive beaded wire is gradually expanding into high-precision machining, especially in the high-precision cutting and shaping of hard and brittle materials such as silicon, sapphire, and silicon carbide. This places higher demands on the performance of machining tools, including highly uniform abrasive grain distribution, stable structural bonding, and controllable cutting processes, to achieve higher dimensional accuracy, lower surface damage, and better processing consistency. However, the current production of abrasive beads is still mainly manual, resulting in low production efficiency, disordered abrasive grain arrangement, poor product consistency, and large fluctuations in finished product quality. This makes it difficult to meet the high stability and consistency requirements of precision machining, thus limiting its application in high-end manufacturing.

[0003] Abrasive wire saws, as the core working unit, are widely used in stone quarrying, slab cutting, and irregular shape processing, as well as in the high-precision cutting and shaping of hard and brittle materials such as silicon, sapphire, and silicon carbide. Currently, most abrasive wire saws are manufactured using hot-pressing sintering or electroplating processes, with the abrasive grains mechanically embedded into the substrate surface. This method suffers from insufficient holding force and a tendency to detach. With increasing demands for high efficiency, low wear, and narrow kerf in material processing, smaller diameter abrasive wire saws are gradually becoming the development trend. However, as the diameter of the wire saw decreases, the surface chip space is significantly reduced, leading to chip accumulation, accelerated abrasive wear, and decreased cutting performance during the cutting process. Summary of the Invention

[0004] The first objective of this invention is to provide a spiral bead to solve at least one of the technical problems existing in current abrasive beads.

[0005] The technical solution of the present invention is as follows:

[0006] A spiral bead, comprising beads with an outer diameter of 0.5–20 mm, includes a bead base, wherein the outer circumferential surface of the bead base is sequentially provided with an anti-wear ring, a dense spiral zone, a loose spiral zone, and a chip removal ring; wherein:

[0007] The anti-wear ring and the chip removal ring are both circular ring structures;

[0008] The spiral dense region and the spiral loose region are respectively provided with a binder spiral coating region to form a spiral structure with a preset pitch; abrasive particles are distributed and fixed on the binder spiral coating region; the abrasive particles and the binder combine to form an abrasive body region, and the binder, abrasive particles and bead matrix in the binder spiral coating region form a metallurgical bond.

[0009] Preferably, the spiral beads are fine-diameter beads with an outer diameter of 0.5 to 4 mm.

[0010] Preferably, the binder is a metal binder.

[0011] Furthermore, the spiral density of the dense spiral zone is 5 to 15 spirals per centimeter, and the spiral density of the loose spiral zone is 1 to 10 spirals per centimeter, with the number of spirals per centimeter in the dense spiral zone being greater than that in the loose spiral zone. The spiral end of the dense spiral zone is connected to an anti-wear ring to protect the spiral end and prevent excessive wear. The chip removal ring is spaced, for example, 0.5mm-5mm, from the end of the loose spiral zone to allow sufficient space for chip removal.

[0012] Furthermore, the spiral abrasive particles in the spiral dense zone and the spiral loose zone each have a projected width (i.e., the width of a single-turn spiral abrasive particle) in the axial direction of the bead string, and the projected width is 0.1 mm to 3 mm; wherein, in the spiral dense zone, the ratio of the projected width to the spiral dense zone pitch is 0.4 to 0.7; and in the spiral loose zone, the ratio of the projected width to the spiral loose zone pitch is 0.3 to 0.6, thereby ensuring effective coverage of abrasive particles while forming a stable chip removal channel between adjacent spiral abrasive particles.

[0013] Furthermore, the spirals in the dense and loose spiral regions are distributed with equal or variable pitch. Specifically, the spirals in the dense and loose spiral regions exhibit a regular normal distribution or an irregular, disordered transition. In the dense spiral region, the pitch transitions from dense to sparse, while in the loose spiral region, the pitch exhibits a regular normal distribution, a gradual functional increase, or an irregular, disordered arrangement.

[0014] Another object of the present invention is to provide a beaded cord comprising a plurality of functional units, each of which comprises one to a plurality of beads; preferably one to four beads.

[0015] The functional unit includes at least an anti-wear ring, a spiral dense area, a spiral loose area, and a chip removal ring; the anti-wear ring, the spiral dense area, the spiral loose area, and the chip removal ring are simultaneously arranged on the same bead, or are respectively arranged on multiple beads;

[0016] The spiral dense zone and spiral loose zone are each provided with a binder spiral coating zone, forming a spiral structure with a preset pitch; abrasive particles are distributed and fixed on the binder spiral coating zone; the binder, abrasive particles, and bead matrix in the binder spiral coating zone form a metallurgical bond. The anti-wear ring and chip removal ring each have at least one annular structure, preferably 1-3 annular structures. The binder, abrasive particles, and bead matrix in the anti-wear ring and chip removal ring also form a metallurgical bond.

[0017] The present invention also provides a spiral bead manufacturing apparatus, comprising a continuous feeding assembly, a feeding coating assembly, an abrasive coating assembly, and a mold assembly; wherein the continuous feeding assembly, the feeding coating assembly, and the abrasive coating assembly are arranged sequentially, and the mold assembly is located on the side of the abrasive coating assembly; wherein...

[0018] Continuous feeding assembly: includes a bead rod lifting mechanism and a bead rod transfer mechanism; the bead rod lifting mechanism includes at least two lifting cylinders, each lifting cylinder is connected to a lifting block for lifting a single bead rod, and the lifted bead rod is automatically transferred to the bead rod transfer mechanism; the bead rod transfer mechanism includes a motor-driven feed screw and a slide rail slider that cooperates with the feed screw, the slide rail slider is provided with a semi-conical groove plate, the semi-conical groove plate is used to receive the bead rod transferred from the bead rod lifting mechanism; when the slide rail slider moves, it sends the bead rod on the semi-conical groove plate to the bead rod clamping and rotating mechanism of the feeding coating assembly;

[0019] The feed coating assembly includes a bead clamping and rotating mechanism, a bead advancing mechanism, and a solder coating mechanism. The bead clamping and rotating mechanism includes a rotary clamping cylinder and a three-jaw chuck to clamp and rotate the bead. The bead advancing mechanism includes a coating feed screw and a slide that cooperates with the coating feed screw. The rotary clamping cylinder is located on the slide. The solder coating mechanism includes a dispensing unit that works with the bead clamping and rotating mechanism and the bead advancing mechanism to perform pitch-type coating on the bead. The coated bead is then fed to the bead clamping mechanism of the abrasive coating assembly via the movement of the bead advancing mechanism.

[0020] The abrasive coating assembly includes a bead bar clamping mechanism, a vibrating sand dropping mechanism, an abrasive recycling mechanism and a station conversion mechanism; the bead bar clamping mechanism includes a cylinder body and jaws on the cylinder body; the jaws face the incoming material direction to clamp the bead bar sent by the feeding and coating assembly; the vibrating sand dropping mechanism includes a bracket erected above the bead bar clamping mechanism; a vibrating screen for abrasive dropping is connected to the bracket; the abrasive recycling mechanism is located below the vibrating sand dropping mechanism; the station conversion mechanism includes a load-bearing bottom plate, and the load-bearing bottom plate cooperates with a station conversion screw rod to achieve lateral movement, and move the bead bar under the mold loading assembly;

[0021] The mold loading assembly includes a pneumatic clamping mechanism and a transfer and mold loading mechanism to clamp and transfer the bead bar coated with abrasives to a preset position.

[0022] Further, in the continuous feeding assembly, two bead placing brackets are provided beside the bead bar lifting mechanism, and the two ends of the bead bar are respectively placed on these two bead placing brackets; a bead bar position correction block is provided beside the lifting cylinder; the top of the bead bar position correction block is an inclined surface, and the side of this inclined surface close to the bead placing bracket is high, and the side close to the semi-conical notch plate is low, so that the bead bar can automatically roll and transfer to this semi-conical notch plate.

[0023] Further, in the feeding and coating assembly, the bead bar advancing mechanism further includes two coating optical axes respectively arranged on both sides of the coating feed screw rod; the sliding table cooperates with the coating feed screw rod, and both sides of the sliding table are respectively slidably arranged on the two coating optical axes and can slide along the coating optical axes.

[0024] Further, in the feeding and coating assembly, a height adjustment device for adjusting the height of the bead bar is further included.

[0025] Further, in the abrasive coating assembly, a sand dropping screw rod is provided on the horizontal rod in the middle of the bracket of the vibrating sand dropping mechanism, and a funnel connecting frame is provided on the sand dropping screw rod, and this funnel connecting frame connects the vibrating screen.

[0026] Further, in the abrasive coating assembly, a transfer screw rod in the left-right direction and a second slide rail arranged in parallel with this transfer screw rod are provided on the upper surface of the load-bearing bottom plate, and a third motor drives the transfer screw rod to work; a cylinder mounting plate is provided on the transfer screw rod, and this cylinder mounting plate can move left and right under the cooperation of the transfer screw rod and the second slide rail; an abrasive recycling hopper is provided on the load-bearing bottom plate.

[0027] Further, in the mold loading assembly, the transfer and mold loading mechanism includes a transfer bracket, a mold loading screw rod in the front-back direction is provided in the middle of the transfer bracket, a mold loading optical axis is respectively arranged in parallel on both sides of the mold loading screw rod, and a "U"-shaped slider cooperating with this mold loading screw rod is provided on the mold loading screw rod, and both ends of this slider cooperate with the two mold loading optical axes respectively.

[0028] Furthermore, the pneumatic gripping mechanism includes mini cylinders mounted on each side plate of the slider; a slide rail connecting block is fixed on the mini cylinder push rod of the mini cylinder, and the slide rail connecting block slides in cooperation with the mini slide rail provided on the "U"-shaped side plate, so that when the push rod of the mini cylinder moves, it can drive the slide rail connecting block to move up and down along the mini slide rail; a gripper cylinder is provided on the slide rail connecting block, and the lower end of the gripper cylinder is connected to the gripper. When the gripper cylinder is working, it can control the gripper to open or close, so as to grip or release the bead bar.

[0029] This invention also provides a method for preparing spiral beads, using the aforementioned spiral bead manufacturing equipment, and the method specifically includes the following steps:

[0030] (1) Bead rod assembly steps: one or more bead bases are fitted onto the mandrel to form a bead rod; the mandrel is preferably a high temperature resistant mandrel, for example, one that can withstand the temperature of brazing;

[0031] (2) Continuous feeding step: Multiple bead rods for preparing abrasive beads are placed horizontally on two bead placement brackets of the continuous feeding assembly; a single bead rod is lifted by at least two lifting cylinders and lifting blocks in the bead rod lifting mechanism, so that it automatically rolls down along the inclined surface of the bead rod position correction block and is positioned in the semi-conical slot plate of the bead rod transfer mechanism; then, the feed screw driven by the motor drives the slide rail slider to transfer the bead rod at a constant speed to the feed coating assembly;

[0032] (3) Spiral coating step of brazing filler metal: The bead clamping and rotating mechanism of the feeding coating assembly clamps one end of the bead rod through a rotating clamping cylinder and a three-jaw chuck, and drives the bead rod to rotate at a constant speed around the axis of the bead rod; at the same time, the bead rod advancing mechanism drives the slide table to advance axially along the coating optical axis through the coating feed screw, so that the bead rod keeps advancing; the dispensing unit of the brazing filler metal coating mechanism, under the control of PLC, synchronously performs quantitative extrusion and back suction of brazing filler metal according to the preset pulse frequency, and forms a spiral brazing filler metal layer on the surface of the bead rod by coordinating the rotation speed of the bead rod and the axial feed speed; the spiral pitch is controllably adjustable by changing the feed speed, and the coating mode includes constant pitch or variable pitch.

[0033] (4) Abrasive coating step: The beaded rod coated with brazing filler metal is fed into the abrasive coating assembly by the feeding coating assembly. The beaded rod is held by the cylinder and jaws of the beaded rod clamping mechanism, and the beaded rod is driven to the coating station by the flip drive motor. The vibrating sand removal mechanism moves at a constant speed along the axial direction of the beaded rod by the sand removal screw through the vibrating screen. At the same time, the vibration generator makes the abrasive particles fall evenly and adhere to the surface of the brazing filler metal. The abrasive particles that do not adhere fall into the abrasive particle recycling hopper for recycling and reuse.

[0034] (5) Mold transfer step: After the abrasive coating is completed, the station conversion mechanism moves the bead bar laterally to the bottom of the mold assembly through the cooperation of the base plate and the station conversion screw; the pneumatic clamping mechanism of the mold assembly pushes the slide rail connecting block down along the mini slide rail through the mini cylinder, the gripper cylinder clamps the bead bar and lifts it up, and the transfer mold assembly mechanism drives the bead bar to the preset position of the mold template through the mold assembly screw for placement;

[0035] (6) Post-processing steps: Vacuum brazing is performed on the entire coated bead rod to allow the brazing filler metal to climb up and wrap around the root of the abrasive grains, forming a strong bond; finally, the processed beads are removed from the bead rod one by one to obtain spiral abrasive beads; or they are removed and cut and separated again to obtain spiral abrasive beads.

[0036] Furthermore, the beaded rod is made by inserting multiple 10mm long stainless steel hollow tubes into a solid stainless steel support rod. A quick-drying adhesive is used to form a tight connection between the base and the support rod, preventing axial rotation and radial movement.

[0037] Furthermore, the dispensing valve uses a PLC signal to extrude a fixed amount of solder, and after coating is completed, it generates a certain back suction force to draw back the excess solder.

[0038] Furthermore, the abrasive coating assembly continuously recovers abrasive grains that do not adhere to the surface of the brazing filler metal during the abrasive grain feeding process through the hopper, thereby improving the reuse rate of abrasive grains.

[0039] The beneficial effects of this invention are as follows:

[0040] 1. The beads of the present invention, through the spiral structure design, (1) the abrasive distribution structure formed on the surface of the beads is conducive to improving the stress distribution state during the cutting process; (2) a continuous chip removal channel is formed between the spiral trajectories, which improves the chip capacity and reduces the risk of blockage; (3) a composite functional structure of "spiral structure high-efficiency cutting + chip removal channel + chip removal ring" is constructed, so that the beads are constructed with cutting, chip storage and chip removal functional areas, realizing high-efficiency cutting and smooth chip removal, and improving chip removal efficiency; (4) the design of the front anti-wear ring effectively avoids the problem of excessive wear of the beads caused by high-speed impact during cutting processing; (5) by forming a metallurgical bond, the abrasive holding strength is improved and the stability under high load conditions is enhanced; (6) under the condition of small diameter, it still has excellent cutting performance and service life, and at the same time, it is conducive to realizing the requirements of small kerf and high-precision processing; (7) in precision processing applications, it helps to reduce the chipping rate and subsurface damage, improve the integrity of the processed surface, and meet the requirements of high-quality cutting for semiconductor material processing.

[0041] 2. The beaded rope of the present invention, by combining spiral beads and flexible base rope, (1) optimizes the arrangement and forming process of abrasive beads, realizes the orderly or controllable distribution and stable bonding of abrasive beads on the surface of the beaded rope, improves the uniformity of abrasive distribution and structural consistency, thereby improving the dimensional consistency and processing accuracy during the processing; (2) the bonding strength of abrasive beads is improved, and abnormal detachment is not likely to occur during the processing, thereby enhancing wear resistance and extending service life, while reducing the risk of processing defects caused by abrasive detachment; (3) during continuous cutting, the abrasive beads are subjected to force More uniform, the cutting compensation between adjacent beads is achieved through structural size or morphological differences, making the wear process more controllable and improving the stability of cutting performance; (4) It can obtain a neater and straighter cut, reduce edge chipping and surface damage during processing, reduce surface roughness, and improve the quality of the processed surface, which is especially suitable for high-precision cutting of hard and brittle materials; (5) While improving processing efficiency, it also takes into account processing quality and service life, which is suitable for precision processing scenarios with high requirements for dimensional accuracy, surface integrity and stability, including the cutting and processing of semiconductor materials (such as silicon wafers, sapphire, etc.).

[0042] 3. The spiral abrasive bead manufacturing equipment and method disclosed in this invention:

[0043] (1) Automation significantly improves efficiency and consistency: This equipment integrates four major modules: continuous feeding, feed coating, abrasive coating, and mold assembly, forming a complete automated production line. From the automatic feeding and positioning of the bead rods, to the precise coating of spiral brazing wire on the surface of the rotating bead rods, to the uniform spreading of abrasive particles on the vibrating screen (and further recycling of residual material), and finally the automatic clamping and mold assembly, the entire process can be automated. This greatly liberates labor and enables efficient, stable, and mass production of spiral abrasive beads with a fine diameter of 0.5mm to 20mm. The product specification consistency is far superior to that of traditional manual preparation.

[0044] (2) Spiral coating process to optimize tool performance: The feed coating assembly of this invention precisely clamps and rotates the beaded rod through a rotary clamping cylinder and a three-jaw chuck, while the coating feed screw drives its axial movement at a uniform speed. During this process, the dispensing valve, precisely controlled by a PLC, coordinates the rotation and feed speeds according to a preset program to coat a uniform spiral solder layer on the surface of the beaded rod. This method not only supports constant pitch coating, but also enables various complex variable pitch coatings (such as pitch gradually changing from large to small on the left, pitch exponent smoothly decreasing, pitch increasing according to a function, etc.).

[0045] (3) Reliable structural design and smooth, stable operation: The connection between each assembly and the internal structural design ensure the smoothness and reliability of the automated process. For example, the continuous feeding assembly realizes the automatic, orderly, single-piece separation and precise placement of the bead rods through the lifting cylinder and the position correction block with the inclined surface. The station conversion mechanism in the abrasive coating assembly can move the bead rods smoothly and accurately below the sand coating station and the mold assembly station through the cooperation of the lead screw and the slide rail. The mold assembly realizes the gentle and accurate clamping and placement of the coated finished product through the coordination of the mini cylinder, the micro slide rail and the gripper cylinder. In addition, the equipment is also equipped with a bead rod height adjustment device, a dispensing valve extrusion force adjustment mechanism and other mechanisms, which allow for fine adjustment of process parameters and enhance the adaptability of the equipment to products of different specifications and the controllability of the process.

[0046] (4) Fully automated production can be achieved. Operators are completely freed from repetitive and dusty manual operations such as applying glue and spreading sand. This not only reduces labor intensity but also reduces workers' direct contact with chemical adhesives (brazing filler metal) and dust, thereby improving the working environment and enhancing production safety.

[0047] In summary, this invention provides an automated production equipment for spiral abrasive beads. The continuous feeding assembly continuously supplies the substrate to the equipment, and the brazing filler metal coating mechanism completes the spiral coating of brazing filler metal at equal intervals and thicknesses. The automation of this process can greatly improve the production efficiency of abrasive beads and ensure the consistency of abrasive bead specifications. Attached Figure Description

[0048] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0049] Figure 1 This is a schematic diagram of the beaded structure in Embodiment 1 of the present invention.

[0050] Figure 2 This is a partial structural diagram of the beads in Embodiment 1 of the present invention.

[0051] Figure 3 This is one of the structural schematic diagrams of the beaded rope in Embodiment 2 of the present invention.

[0052] Figure 4 This is the second schematic diagram of the structure of the beaded rope in Embodiment 2 of the present invention.

[0053] Figure 5 These are diagrams showing different arrangements of the beads on the beaded cord of this invention, where A to G represent different types, sizes, shapes, and dimensions of spiral beads. 5-1 to 5-5 represent different arrangement methods.

[0054] Figure 6 This is a schematic diagram of the overall structure of the automated preparation equipment for spiral abrasive beads according to Embodiment 3 of the present invention;

[0055] Figure 7 This is one of the schematic diagrams of the continuous feeding assembly structure;

[0056] Figure 8 This is the second schematic diagram of the continuous feeding assembly structure;

[0057] Figure 9 This is one of the schematic diagrams of a beaded rod lifting mechanism;

[0058] Figure 10 This is the second schematic diagram of the beaded rod lifting mechanism;

[0059] Figure 11 This is a schematic diagram of the gripping rotary feed mechanism;

[0060] Figure 12 This is a schematic diagram of the bead-stringing rod clamping and rotating mechanism;

[0061] Figure 13 This is a schematic diagram of the solder coating mechanism;

[0062] Figure 14 This is a schematic diagram of the dispensing valve structure;

[0063] Figure 15 This is a schematic diagram of the height adjustment structure for the beading rod;

[0064] Figure 16 This is a schematic diagram of the bead bar clamping and abrasive coating mechanism;

[0065] Figure 17 This is a schematic diagram of the bead-holding mechanism;

[0066] Figure 18 This is a schematic diagram of an automatic abrasive feeding structure;

[0067] Figure 19 This is a schematic diagram of the abrasive coating lifting structure;

[0068] Figure 20 This is a schematic diagram of the clamping and molding mechanism; the view is from bottom to top.

[0069] Figure 21 This is a schematic diagram of the transfer section of the mold assembly mechanism;

[0070] Figure 22 This is a schematic diagram of the clamping part of the mold assembly mechanism;

[0071] The diagram is marked as follows:

[0072] 1. Continuous feeding assembly; 2. Feed coating assembly; 3. Abrasive coating assembly; 4. Mold assembly.

[0073] 10. Rope core; 11. Bead matrix; 12. Spiral coating area of ​​brazing filler metal; 13. Diamond abrasive grains; 14. Chip removal channel;

[0074] 101. Anti-wear ring; 102. Dense spiral zone; 103. Loose spiral zone; 104. Chip removal ring;

[0075] 110. First string of beads; 120. Second string of beads; 130. Third string of beads; 140. Fourth string of beads;

[0076] 1001. First motor; 1002. Feed screw; 1003. Bead bar; 1004. Lifting cylinder; 1005. Connecting block between slide rail and screw; 1006. Bead bar position correction block; 1007. Bead placement bracket; 1008. Slide rail slider; 1009. Semi-conical groove plate; 1010. Guide rail.

[0077] 1101. Coating optical axis; 1102. Rotary clamping cylinder; 1103. Belt; 1104. Second motor; 1105. Coating feed screw; 1106. Hollow connecting column; 1107. Three-jaw chuck; 1108. Pulley; 1111. Motor; 1112. Slide table.

[0078] 1201. Clamping cylinder; 1202. Dispensing valve; 1203. Lifting cylinder; 1204. Cylinder connecting plate; 1205. Height adjustment device connecting plate; 1206. Height adjustment device; 1207. Upper and lower pressure blocks of beaded rod; 1208. Dispensing valve extrusion force adjustment knob; 1209. Dispensing valve body; 1210. Dispensing valve needle; 1211. Lifting upper support plate; 1212. Lifting knob; 1213. Lifting base; 1214. Rotating ejector pin.

[0079] 1301. Third motor; 1302. Cylinder mounting plate; 1303. Station conversion screw; 1304. Second slide rail; 1305. Transfer screw; 1306. Parallel lifting cylinder; 1307. Abrasive grain recovery hopper; 1308. Fourth motor; 1309. Horizontal screw; 1310. Cylinder connector; 1311. Motor connecting cylinder body; 1312. Cylinder body; 1313. Four-finger gripper; 1314. Loading base plate; 1315. Tilting drive motor.

[0080] 1401. Fifth motor; 1402. Sand dropping screw; 1403. Stirring motor; 1404. Screen; 1405. Spring; 1406. Vibration generator; 1407. Funnel connecting frame; 1408. Fixing plate.

[0081] 1501. Transfer bracket; 1502. Mini cylinder; 1503. Sixth motor; 1504. Mold mounting template; 1505. Mold mounting optical shaft; 1506. Mold mounting lead screw; 1507. Mini cylinder mounting block; 1509. Mini slide rail; 1510. Mini cylinder push rod; 1511. Slide rail connecting block; 1512. Grip cylinder mounting plate; 1513. Grip cylinder.

[0082] 1601, Lifting three-axis cylinder; 1602, Lifting positioning plate. Detailed Implementation

[0083] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solutions of the present invention, and to facilitate its implementation.

[0084] Example 1: Beading

[0085] The beaded string provided by this invention includes a beaded string substrate and one or more segments of an abrasive body spirally wound and fixed to the outer surface of the beaded string substrate. The abrasive body is composed of abrasive grains and a binder. The abrasive body has a structure with superhard abrasive grains internally bonded or a structure with superhard abrasive grains bonded to its outer surface. The abrasive grains are diamond or cubic boron nitride. The binder is used to fix the abrasive grains to the beaded string substrate, and the binder is selected from metal binders; wherein the metal binder is one or more of brazing filler metal, sintered metal, or electroplated metal. In this embodiment, brazing filler metal is specifically used as the binder.

[0086] See Figures 1 to 4 The present invention provides a bead, including a bead substrate 11 (generally a metal substrate, including but not limited to stainless steel, iron-based alloys, non-ferrous metals and alloys, special metal substrate round tubes, etc.), and a binder coating area (i.e., the solder spiral coating area 12 in this embodiment) and a chip removal channel 14 disposed on the outer surface of the bead substrate 11.

[0087] The beads have a small diameter structure with an outer diameter of 0.5–20 mm; preferably, the outer diameter is 1.5–4 mm.

[0088] The brazing filler spiral coating area 12 forms a spiral structure with a preset pitch; diamond abrasive grains 13 are distributed and fixed on the brazing filler spiral coating area 12; an interval region is formed between adjacent spiral structures, and the interval region constitutes a chip removal channel 14, thereby forming a functional structure of "alternating distribution of spiral abrasive grain area and chip removal channel" on the surface of the beads; the brazing filler spiral coating area 12 forms a metallurgical bond with the bead substrate and diamond abrasive grains 13 by brazing.

[0089] The solder spiral coating region 12 is formed by mixing metal solder powder with an organic binder. The solder powder is an alloy solder containing active elements. The active elements include at least one of Ti, Cr, or B, and the solder is one or more combinations of copper-based, nickel-based, or iron-based solders. The mass ratio of the solder powder to the organic binder is 7:3 to 95:5.

[0090] The pitch of the spiral structure is 0.5–5 mm, and the thickness of the brazing filler layer is 0.1–0.5 mm. The shape and pitch of the spiral structure can be adjusted according to different working conditions. The chip removal channel is an axially continuous or non-continuous groove structure with a width of 0.2–2 mm, which, in conjunction with the spiral structure, forms an intermittent contact cutting mode to reduce cutting resistance and improve chip removal efficiency.

[0091] Abrasive grains (e.g., diamond grains) are partially embedded within the brazing filler metal layer and partially exposed on the outer surface. The protrusion height of the abrasive grains is 20%–80% of their grain diameter, forming a cutting edge structure and improving the grain holding strength and wear resistance. The diamond grains are partially embedded in the brazing filler metal layer and partially exposed on the outer surface to form a cutting edge structure. The abrasive grains and brazing filler metal combine to form an abrasive body. The cross-section of the abrasive body can be a triangular thread, trapezoidal thread, sawtooth thread, rectangular thread, etc.

[0092] Furthermore, the beads provided by this invention include a cylindrical bead base 11. From left to right, the outer circumferential surface of the bead base 11 is provided with an anti-wear ring 101, a dense spiral zone 102, a loose spiral zone 103, and a chip removal ring 104. The anti-wear ring 101 is a circular ring structure, its function being to prevent excessive wear from the abrasive particles in the spiral zone. Its height is consistent with the solder spiral coating zone 12 of the spiral zone. The anti-wear ring 101 contains abrasive particles. During the use of the beads, the end of the spiral zone first encounters the material to be processed, resulting in the fastest wear and often forming conical wear at the end. Forming an anti-wear ring at the end of the spiral zone can greatly reduce the occurrence of conical wear.

[0093] The spiral density of the spiral dense area 102 is 5-15 spirals per centimeter (one spiral is 360 degrees around the circumference). Since this area comes into contact with the material to be processed first and has a heavy workload, it needs to be densely distributed to reduce wear. The spiral ends of the spiral dense area can be connected to anti-wear rings 101 so that the spiral ends are protected by anti-wear rings 101.

[0094] The spiral density of the loose spiral zone 103 is 1 to 10 spiral turns per centimeter. Since this zone comes into contact with the material being processed last, the workload is relatively light, and a large amount of debris has already been generated. Therefore, a loose distribution is necessary to accommodate the debris during processing. A transition zone may or may not be provided between the dense spiral zone and the loose spiral zone. The two ends of the spiral structure in the transition zone connect to the ends of the spirals in the dense and loose spiral zones, respectively. The spiral density of the spiral turns in the transition zone is between that of the dense spiral zone and the loose spiral zone. The length of the transition zone can be set to 1 / 20 to 1 / 5 of the length of either the dense or loose spiral zone.

[0095] The chip removal ring 104 is also a circular structure, its function being to discharge as much debris as possible from the spiral dense zone 102 and the spiral loose zone 103, preventing it from being carried into the next string of beads and thus increasing the workload of the next string of beads. The height of the chip removal ring 104 is consistent with the solder spiral coating zone 12 of the spiral zone. The chip removal ring 104 contains abrasive particles, and there is a distance between the chip removal ring 104 and the end of the spiral loose zone, for example, 0.5mm-5mm, to allow sufficient space for chip removal; the preferred distance is 2-5mm.

[0096] In the dense spiral zone 102 and the loose spiral zone 103, the brazing filler metal coating can be of constant pitch, variable pitch, or a combination thereof. Constant pitch coating refers to the bonding agent being applied spirally along the outer surface of the beaded substrate with a preset constant pitch. Variable pitch coating can be further subdivided into three types: a pitch that gradually decreases from left to right, a pitch that decreases exponentially, and a pitch that increases functionally. In variable pitch coating, the magnitude and range of pitch variation are determined by different operating conditions. The cross-section of the abrasive body can be a triangular thread, a trapezoidal thread, a sawtooth thread, a rectangular thread, etc.

[0097] Example 2: Beaded Rope

[0098] Beaded cord is a linear tool that connects multiple beads into a continuous loop to solve the problem of continuous cutting that cannot be achieved with a single bead. Multiple beads are strung together through a cord core to form a beaded cord. The through-hole in the center of each bead allows the cord core to pass through; the cord core includes, but is not limited to, stainless steel wire, high-carbon steel solid wire core, aramid fiber core, etc.

[0099] In one embodiment of the beaded cord of the present invention, multiple beads of Embodiment 1 are used as functional units; this is Method 1. The multiple functional units are arranged at intervals, or arranged at intervals and tightly connected in combination.

[0100] In another embodiment, the present invention provides a beaded cord comprising a first bead 110, a second bead 120, a third bead 130, and a fourth bead 140. The first bead 110 has an anti-abrasion ring 101, the second bead 120 has a dense spiral area 102, the third bead has a loose spiral area 103, and the fourth bead 140 has a chip removal ring 104. The first bead 110 to the fourth bead 140 can be tightly connected end-to-end to form a functional unit (e.g., embodiment two). Figure 4 ), or arranged in intervals (method three, such as Figure 3 ); or simultaneously having both closely connected and spaced arrangement (method four), for example, the first string of beads 110 and the second string of beads 120 are closely connected, the third string of beads 130 and the second string of beads 120 have a gap, and the fourth string of beads 140 and the third string of beads 130 have a gap.

[0101] The spacing between the beads depends on the properties of the material being processed. For example, softer stone, which is prone to chipping, can be processed using method three or four. Harder, more difficult-to-process materials can be processed using method one or two.

[0102] In another embodiment, a functional unit may be composed of only two or three beads. When two beads are used, the anti-wear ring 101 and the spiral dense area 102 are located on the first bead; the spiral loose area 103 and the chip removal ring 104 are located on the second bead. If three beads are used, the anti-wear ring 101 and the spiral dense area 102 are located on the first bead, and the spiral loose area 103 and the chip removal ring 104 are located on the second and third beads, respectively. Alternatively, the anti-wear ring 101 and the chip removal ring 104 are located on the first and third beads, respectively, and the spiral dense area 102 and the spiral loose area 103 are located on the second bead, etc.

[0103] When using two or three beads, the beads can be tightly connected, spaced apart, or a combination of tightly connected and spaced apart.

[0104] In another embodiment, the functional unit is not limited to 1-4 beads; a larger number of beads can also be used to form a functional unit, such as two beads in the spiral dense area, two beads in the spiral loose area, one bead in the anti-wear ring, and one bead in the chip removal ring.

[0105] Beaded cords can consist solely of abrasive beads and a flexible base cord. The abrasive beads are sequentially threaded into the flexible base cord and then fixed in place to form the beaded cord. Alternatively, beaded cords can consist of abrasive beads, a flexible base cord, and a protective sleeve. The protective sleeve is fitted onto the flexible cord between the abrasive beads and between adjacent abrasive beads to separate adjacent beads and protect the flexible base cord between them from abrasion. The abrasive beads are fixed to the flexible base cord at equal or variable intervals. The helical winding structure of each abrasive bead can be identical, different, or a combination according to a predetermined pattern. Specifically, as shown... Figure 5 As shown. Figure 5 Part 5-1 consists of an ordered arrangement of identical abrasive beads. Figure 5 Part 5-4 is a random arrangement of identical abrasive beads; Figure 5 Part 5-2 shows the arrangement and combination of abrasive beads with different structures. Figure 5 Part 5-3 of the text represents an arrangement and combination of abrasive beads with various structures; it can also be a random arrangement and combination, such as... Figure 5 Section 5-5. Among them, abrasive beads with different structures can achieve synchronous correction and complementary positions during the cutting process, ensuring optimal cutting performance. The flexible matrix rope is connected end-to-end via a butt joint or can be made into a seamless ring structure through weaving.

[0106] In the figure, A to G represent the beads in Example 1, including the anti-wear ring 101, the dense spiral area 102, the loose spiral area 103, and the chip removal ring 104. However, each bead has a different spiral density or a spiral with a different angle.

[0107] The manufacturing method of beads and beaded cords specifically includes: applying abrasive particles to the surface of the bead substrate 11 through a spiral coating process, thereby achieving spiral coating of the beads; after coating is completed, powder is sprinkled onto the beads to ensure that the abrasive particles are fully distributed throughout the coating area; after the abrasive coating is completed, the entire bead rod is vacuum brazed to ensure that the abrasive particles are firmly attached to the bead substrate 11; and then the beads are removed from the stainless steel support rod to obtain a single fine-diameter spiral abrasive bead.

[0108] like Figure 2 As shown in the figure, this is a schematic diagram of the bead structure after processing and sintering. The spiral beads are obtained through a series of operation processes. In the spiral beads, the abrasive grains are firmly locked on the binder and also adhered to the bead substrate 11 through high-temperature sintering.

[0109] Example 3 Manufacturing equipment and method

[0110] See Figure 6An automated preparation device for producing spiral abrasive beads as described in Example 1 or Example 2 mainly comprises four parts: a continuous feeding assembly 1, a feeding coating assembly 2, an abrasive coating assembly 3, and a mold assembly 4. The continuous feeding assembly 1, the feeding coating assembly 2, and the abrasive coating assembly 3 are arranged sequentially from left to right, with the mold assembly 4 located in front of the abrasive coating assembly 3.

[0111] The continuous feeding assembly 1 includes a bead-bar lifting mechanism and a bead-bar uniform speed transfer mechanism. See also... Figures 7 to 10 The continuous feeding assembly 1 includes: a first motor 1001, a feed screw 1002, a lifting cylinder 1004, a slide rail and screw connecting block 1005, a bead rod position correction block 1006, a bead placement bracket 1007, a slide rail slider 1008, a semi-conical groove plate 1009, and a guide rail 1010.

[0112] The beaded rod uniform speed transfer mechanism is as follows: The feed screw 1002 and guide rail 1010 are arranged in parallel. The slide rail and screw connecting block 1005 cooperates with the screw. Rotation of the feed screw 1002 drives the slide rail and screw connecting block 1005 to move left and right along the guide rail 1010. The first motor 1001 drives the feed screw 1002 to rotate. A slide rail slider 1008 is fixedly connected to the slide rail and screw connecting block 1005. A semi-conical groove plate 1009 (referred to as the left groove plate) is fixedly fixed on the slide rail slider 1008. Another semi-conical groove plate 1009 (referred to as the right groove plate) is fixedly provided at the right end of the guide rail 1010. When the slide rail slider 1008 moves left and right along the slide rail, the left and right groove plates move closer or further apart.

[0113] The bead rod lifting mechanism is as follows: Bead placement brackets 1007 are respectively provided on the left and right sides of the guide rail 1010, and the two ends of the bead rod 1003 are respectively placed on these two bead placement brackets 1007. Lifting cylinders 1004 for lifting the bead rod 1003 are respectively provided next to the two bead placement brackets 1007, and lifting blocks are provided on the top of the lifting cylinders 1004. A bead rod position correction block 1006 is provided on the side of the bead placement bracket 1007 facing the slide rail and lead screw connection block 1005. The top of the bead rod position correction block 1006 is a slope, which is higher on the side closer to the bead placement bracket 1007 and lower on the side closer to the slide rail and lead screw connection block 1005. The slot of the semi-conical groove plate 1009 faces the bead rod position correction block 1006.

[0114] The continuous feeding assembly 1 is used as follows: Two lifting cylinders 1004 move to raise the lifting block, which lifts a single beaded rod (i.e., a beaded rod 1003 with one or more beaded bases 11) onto the beaded rod position correction block 1006. Specifically, the lifting cylinders 1004 move upward, slowly pushing the beaded rod above the cylinders until the top of the lifting block is higher than the beaded rod position correction block 1006. Since the top of the lifting block is also inclined, the beaded rod automatically rolls towards the top of the beaded rod position correction block 1006. The upper surface of the beaded rod position correction block 1006 is also inclined, so the beaded rod slides freely along the direction of the beaded rod position correction block 1006 onto the semi-conical slot plate 1009. The first motor 1001 operates, and the feed screw 1002 linked to it drives the slide rail and the screw connecting block 1005, thereby driving the left slot plate closer to the right slot plate. The left end of the bead rod 1003 is pushed against the right side of the slide rail and lead screw connecting block 1005, so that the bead rod is pushed from left to right into the feed coating assembly 2 and stably enters the positioning hole of the rotary clamping cylinder 1102 of the clamping rotation mechanism of the feed coating assembly 2.

[0115] The top of the bead placement bracket 1007 is also inclined, so that after one bead rod is lifted, the next one can automatically roll to the position of the previously lifted rod, thus achieving continuous supply.

[0116] The PLC sends pulse signals to drive the motor and control the feeding movement. Two proximity switches are installed on the feed screw 1002, one for the starting position and the other for the ending position. When the bead rod moves to the ending position, the PLC will stop sending pulse signals. This ending position is reached by driving the slide rail and the screw connecting block 1005 to move the bead rod to the proximity switch installed at the other end. At this time, the proximity switch sends an electrical signal, causing the PLC to send a feedback signal, thereby stopping the movement. After that, the first motor 1001 works, controlling the feed screw 1002 to move in the opposite direction, causing the slide rail and the screw connecting block 1005 to return to the starting position to the left.

[0117] See Figures 11 to 16 The feeding coating assembly 2 includes a beaded rod clamping and rotating mechanism, a beaded rod advancing mechanism, and a solder uniform coating mechanism. The beaded rod advancing mechanism includes a coating optical shaft 1101, a belt 1103, a second motor 1104, a coating feed screw 1105, a hollow connecting column 1106, and a pulley 1108. There are two coating optical shafts 1101 arranged in parallel; a coating feed screw 1105 driven by a motor 1111 is located between the two coating optical shafts 1101; a slide table 1112 cooperates with the coating feed screw 1105, and the two sides of the slide table 1112 are slidably mounted on the two coating optical shafts 1101 respectively, and can slide along the coating optical shafts. The beaded rod clamping and rotating mechanism is located on the slide table 1112.

[0118] The bead bar clamping and rotating mechanism includes a rotary clamping cylinder 1102 and a three-jaw chuck 1107. The three-jaw chuck 1107 faces away from the direction from which the bead bar moves in the continuous feeding assembly 1 and is oriented towards the brazing filler metal coating mechanism. A hollow connecting column 1106 is bolted to the rotary clamping cylinder 1102. This hollow column helps the bead bar pass smoothly through the rotary clamping cylinder 1102 and through the three-jaw chuck 1107. The rotary clamping cylinder 1102 and the hollow connecting column 1106, connected to the three-jaw chuck 1107, are connected to a second motor 1104 via a belt 1103, allowing the bead bar to rotate circumferentially along its axis. The rotation speed of the bead bar can be changed by altering the pulse frequency.

[0119] The solder uniform coating mechanism includes a clamping cylinder 1201, a dispensing valve 1202, a lifting cylinder 1203, a cylinder connecting plate 1204, a height adjustment device connecting plate 1205, a height adjustment device 1206, upper and lower pressure blocks 1207 for the bead rod, and a fixed bracket. The height adjustment device 1206 is located below the bead rod's forward path to support it. The dispensing unit (including the dispensing valve 1202, which includes a dispensing valve extrusion force adjustment knob 1208, a dispensing valve body 1209, and a dispensing valve needle 1210) is located above the bead rod's forward path. The upper and lower pressure blocks 1207 include an upper pressure block and a lower pressure block, located above and below the bead rod, respectively. The clamping cylinder 1201 controls the upper and lower pressure blocks 1207 to move closer or further apart. The lifting cylinder 1203 controls the up-and-down movement of the dispensing unit.

[0120] The continuous feeding assembly 1 passes the bead bar through the rotary clamping cylinder 1102 and into the three-jaw chuck 1107. The rotary clamping cylinder and the three-jaw chuck 1107 clamp the bead bar and rotate it at a certain speed. Then, the coating feed screw 1105 drives the slide table 1112, which in turn drives the bead bar to continuously feed along the bead axis, so that it can move horizontally to the glue application position. When the bead bar is fed, the height adjustment device 1206 is used for horizontal positioning. To further maintain stability during the dispensing of the bead rod, the clamping cylinder 1201 presses down vertically, causing the upper and lower clamping blocks 1207 of the bead rod to clamp together, ensuring the bead rod is positioned horizontally without affecting axial movement. The height adjustment device can then fine-tune the position as needed to achieve horizontality. Next, the lifting cylinder 1203 of the dispensing valve 1202 begins to descend, lowering it to the designated coating area. This, combined with the feeding motion of the bead rod, achieves pitch-type coating. After each bead is coated, excess solder is removed and cleaned by the extension and retraction of a telescopic cylinder (not shown in the figure). After all coating processes are completed, the lifting cylinder 1203 returns to its initial position, and the upper and lower clamping blocks 1207 of the bead rod separate. The bead rod advancing mechanism then continues forward, transferring the coated bead rod to the abrasive coating assembly area for the next process.

[0121] In a specific embodiment, the height adjustment device 1206 is as follows: Figure 15 As shown, the device includes a lifting upper support plate 1211, a lifting knob 1212, a lifting base 1213, and a rotating ejector pin 1214. The height adjustment mechanism works by rotating the lifting knob 1212, which controls the engagement of an internal gear set, causing the rotating ejector pin 1214 to deflect at an angle. This causes the rotating ejector pin to rise or fall, changing the position of the upper support plate and maintaining the beads at the same horizontal level for precise coating. In other embodiments, other types of height adjustment mechanisms may also be used.

[0122] Furthermore, after the feeding assembly completes the feeding, the bead rod enters the rotary clamping mechanism. The extension and retraction of the cylinder push rod drives the three-jaw chuck to clamp and release. A pulley is fixed on the motor shaft and the chuck shaft respectively. Through the tension of the belt 1103, the rotation of the second motor 1104 will drive the chuck to rotate together, thereby realizing the uniform rotation of the bead rod. The rotation speed of the bead rod can be controlled by a knob.

[0123] Furthermore, the solder coating is accomplished by the dispensing valve 1202. The dispensing valve's extrusion force can be adjusted by rotating the dispensing valve extrusion force adjustment knob 1208, thereby changing the amount of solder paste extruded. The PLC sends a signal to control the solenoid valve's air circuit, which in turn controls the dispensing valve to extrude the solder. The uniform extrusion motion of the solder accompanies the feeding motion of the bead rod, thus coating the surface of the bead rod with a uniform spiral solder. By controlling the on / off state of the solenoid valve, solder can be uniformly coated onto the surface of the bead rod at intervals. After the solder coating is completed, the dispensing valve can be retracted by a cylinder and extended again when the next bead arrives at the workstation to complete the next solder coating operation.

[0124] During the solder coating process, the following coatings are applied according to different requirements:

[0125] Type 1: Equal pitch bead solder coating method, in which the solder is evenly coated on the beads in equal proportions. The pitch range is determined by the bead rod. For a bead rod with a diameter of 1mm, the optimal pitch is between 0.2-1.2mm; for a bead rod with a diameter of 1.5mm, the optimal pitch is between 0.4-1.6mm; for a bead rod with a diameter of 2mm, the pitch is between 0.6-1.8mm, and so on.

[0126] Type 2: Variable pitch bead solder coating method, which can be further divided into three categories: 1. Pitch gradually changes from left to right, 2. Pitch decreases smoothly by an exponential curve, and 3. Pitch increases by a function.

[0127] Preferably, the pitch variation range in the variable pitch structure corresponds to the dense and loose helical regions on the surface of the beads. The dense helical region has a helical density of 5 to 15 helices per centimeter, corresponding to a pitch of approximately 0.67 mm to 2 mm; the loose helical region has a helical density of 1 to 10 helices per centimeter, corresponding to a pitch of approximately 1 mm to 10 mm. Continuous pitch variation within the above range can be achieved through function adjustment.

[0128] 1) Gradual pitch transition from left to right:

[0129]

[0130] in, These are the positional parameters along the axis of the beads. For position The axial pitch between adjacent helices. The cumulative distribution function of the standard normal distribution. For minimum pitch, For the maximum pitch, and , The position parameter of the pitch change center. This is a parameter for adjusting the width. The function exhibits a monotonically decreasing trend, ensuring a smooth transition of the pitch on the bead surface from larger on the left to smaller on the right, without any abrupt changes. This can be achieved by adjusting the parameter. and It can control the starting position, transition zone width, and rate of pitch change, thereby meeting the design requirements for different abrasive grain arrangement densities and cutting performance. Preferably, A value of 0.5 to 2.0 can be selected to ensure that the pitch varies smoothly within the set range, satisfying the rotation principle of the coating motor and achieving a stable coating process. Preferably, when this function is used for the transition from a loose area to a dense area, A diameter of 1-10mm can be used. A thickness of 0.67–2 mm is acceptable.

[0131] 2) Smoothly decreasing pitch exponent formula:

[0132]

[0133] in, These are the positional parameters along the axis of the beads. For position The axial pitch between adjacent helices. For minimum pitch, For maximum pitch, This is the attenuation control parameter. This function smoothly decreases the pitch from a larger value at the beginning to a smaller value at the end, making it suitable for abrasive bead structures requiring unidirectional tapering arrangement. Preferably, The value can be between 0.8 and 2.0. Preferably, when this function is used for the transition from a loose region to a dense region, A diameter of 1-10mm can be used. A thickness of 0.67–2 mm is acceptable.

[0134] 3) Pitch increases according to a function:

[0135]

[0136] in, These are the positional parameters along the axis of the beads. For position The axial pitch between adjacent helices. For minimum pitch, For maximum pitch, For the rate of change, The larger the value, the greater the rate of change; therefore, different values ​​can be selected according to different working conditions. The value is preferably between 1.2 and 5.6. This function is suitable for structural designs where the pitch gradually changes from a small value to a large value. Preferably, when this function is used for transitioning from a dense region to a loose region, A thickness of 0.67–2 mm is acceptable. A diameter of 1 to 10 mm can be used.

[0137] Furthermore, in the above-mentioned constant pitch or variable pitch coating process, each spiral has a single-turn spiral width. The width of a single helix turn is preferably 0.1 mm to 3 mm, and is less than the pitch at the corresponding position. In the densely spiral region, the ratio of the width of a single spiral turn to the corresponding pitch satisfies... In the loose spiral region, the ratio of the width of a single spiral turn to the corresponding pitch satisfies the following condition: By coordinating the control of the helical width and pitch of a single turn, a stable chip removal channel can be formed while ensuring effective coverage of abrasive grains, thereby improving cutting stability and reducing chip clogging.

[0138] See Figures 16 to 18 The abrasive coating assembly includes a bead-holding mechanism, a vibratory abrasive removal mechanism, an abrasive recycling mechanism, and a station switching mechanism. The bead-holding mechanism includes a motor-connected cylinder 1311, a cylinder 1312, and a four-finger gripper 1313. The cylinder 1312 is located on the side of the motor-connected cylinder 1311, and the four-finger gripper 1313 is located at the end of the cylinder 1312. The four-finger gripper 1313 of the rotating clamping mechanism faces the material feeding direction (towards the coating assembly 2). The clamping and releasing of the four-finger gripper 1313 is achieved by the retraction of the cylinder 1312, while the motor-connected cylinder 1311 drives the four-finger gripper 1313 and the cylinder 1312 to rotate, thereby clamping and rotating the bead-holding rods fed from the coating assembly 2. A flipping drive motor 1315 is located on the other side of the cylinder mounting plate 1302, driving the motor-connected cylinder 1311 and the cylinder 1312 to rotate. Among them, the four-finger gripper 1313 is equipped with a parallel lifting cylinder 1306 in the material feeding direction. The height of the bead rod is finely adjusted by raising and lowering the parallel lifting cylinder 1306, so as to assist the four-finger gripper 1313 in fixing the bead rod laterally.

[0139] The workstation conversion mechanism consists of a third motor 1301, a cylinder mounting plate 1302, a workstation conversion lead screw 1303, a second slide rail 1304, and a transfer lead screw 1305. The loading base plate 1314, the workstation conversion lead screw 1303, and two horizontal lead screws 1309 arranged parallel to both sides of the workstation conversion lead screw 1303 cooperate to move back and forth. The upper surface of the loading base plate 1314 is provided with a left-right transfer lead screw 1305 and a second slide rail 1304 arranged parallel to the transfer lead screw 1305. The third motor 1301 drives the transfer lead screw 1305. The transfer lead screw 1305 is equipped with a cylinder mounting plate 1302, which cooperates with the transfer lead screw 1305 and the second slide rail 1304 to move left and right. The cylinder mounting plate 1302 is equipped with a cylinder connector 1310, which connects to a rotary clamping mechanism.

[0140] The vibrating sand-removing mechanism consists of a fifth motor 1401, a sand-removing lead screw 1402, a stirring motor 1403, a screen 1404, a spring 1405, a vibration generator 1406, a funnel connecting frame 1407, a fixing plate 1408, and a support. The support is H-shaped and stands vertically above the rotating clamping mechanism and the feed lead screw mechanism. The sand-removing lead screw 1402, driven by the fifth motor 1401, is mounted on a horizontal bar in the middle of the support. A funnel connecting frame 1407, which cooperates with the sand-removing lead screw, is mounted on the sand-removing lead screw 1402. The funnel connecting frame 1407 connects to the screen 1404, which contains four vibration generators 1406. When the vibrators are activated by the PLC, the screen vibrates violently, causing the abrasive particles within the screen to fall onto the beaded surface directly below. An abrasive particle storage bin (not shown in the figure) is also located above the vibrating sand-removing mechanism to provide abrasive particles to the screen 1404.

[0141] The screen is driven to move forward or backward at a constant speed by the sand-dropping screw. The forward and backward speeds can also be controlled by changing the pulse frequency sent to the stepper motor. Through the above coordinated movements, the purpose of uniformly coating abrasive particles can be achieved. An abrasive particle recovery hopper 1307 is set at the bottom of the screen to complete the recovery of uncoated abrasive particles. The abrasive particles falling into the hopper will be drawn back by a strong vacuum generator to generate a strong negative pressure.

[0142] See Figure 19 The parallel lifting cylinder 1306 consists of a lifting three-axis cylinder 1601 and a lifting positioning plate 1602. The upper surface of the lifting positioning plate 1602 is provided with a groove for positioning the bead rod.

[0143] After the feeding and coating mechanism finishes the solder coating, the bead bar will automatically enter the abrasive coating assembly. The bead bar is clamped by the four-finger jaw 1313, and the flipping drive motor 1315 starts to work to drive the bead bar to flip. Then, the transfer screw rod 1305 is driven by the third motor 1301, and the station conversion screw rod 1303 is driven by the fourth motor 1308 to horizontally move the mechanism above the carrier bottom plate 1314, so as to牵引 the bead bar to the designated station, that is, the abrasive coating station. At this time, the bead is located in the area directly below the abrasive dropping mechanism. After completing the above steps, the stirring motor 1403 drives to带动 the vibration generator to vibrate, and the spring releases the excess vibration. The abrasives are evenly scattered onto the screen 1404, and the abrasive dropping mechanism performs uniform dropping to evenly scatter the abrasives on the surface of the solder. The excess abrasives are recycled through the abrasive recovery hopper 1307 for repeated use of the abrasives. During this period, the fifth motor 1401 drives the sand dropping screw rod 1402 to move along the axis direction of the bead, so as to complete the uniform scattering of abrasives on other beads.

[0144] Further, the clamping and rotating mechanism is fixed on the cylinder mounting plate 1302, and the cylinder mounting plate is connected to the transfer screw rod 1305. The screw rod can带动 the clamping and rotating mechanism to move together. After the solder coating is completed, the screw rod带动 the clamping and rotating mechanism to reach the designated station, the jaw cylinder contracts to clamp the bead bar, and the screw rod moves in the reverse direction to带动 the bead bar into the abrasive coating station. An abrasive dropping mechanism is arranged directly above the bead bar. This mechanism is driven by a screw rod, moves at a constant speed with the screw rod, and proximity switches are installed at both ends of the screw rod, with a distance equal to the length of the bead bar. The abrasives are placed in the dropping screen, and the abrasives are stirred by the stirring fan blades connected to the stirring motor 1403. The vibration generator 1406 installed around the dropping screen starts to vibrate to complete the uniform dropping of abrasives. The abrasives that are not adhered to the surface of the solder fall顺势 into the abrasive recovery hopper, and the excess abrasives will be recycled.

[0145] See Figures 20 to 22 , the mold loading assembly 4 includes a pneumatic clamping mechanism and a transfer and mold loading mechanism.

[0146] The transfer and mold loading mechanism includes a transfer bracket 1501. A mold loading screw rod 1506 in the front-back direction is provided in the middle of the transfer bracket 1501. One mold loading optical axis 1505 is provided in parallel on each side of the mold loading screw rod 1506. A "J"-shaped slider that配合 with the mold loading screw rod 1506 is provided on the mold loading screw rod 1506, and both ends of the slider配合 with the two mold loading optical axes 1505 respectively.

[0147] The pneumatic gripping mechanism includes mini cylinders 1502 mounted on each side plate of the slider (i.e., both sides of the "U" shape). The mini cylinders 1502 are mounted on the side plates via mini cylinder mounting blocks 1507. A slide rail connecting block 1511 is fixed to the mini cylinder push rod 1510 of the mini cylinder 1502. This slide rail connecting block 1511 slides in conjunction with a mini slide rail 1509 located on the "U"-shaped side plate, allowing the slide rail connecting block 1511 to move up and down along the mini slide rail 1509 when the push rod of the mini cylinder 1502 moves. A gripper cylinder mounting plate 1512 is provided on the slide rail connecting block 1511, and a gripper cylinder 1513 is provided on the gripper cylinder mounting plate 1512. The lower end of the gripper cylinder 1513 is connected to the gripper. When the gripper cylinder 1513 is working, it can control the gripper to open or close, thereby gripping or releasing the beaded rod.

[0148] The working principle of the mold assembly 4 is as follows: First, the mini cylinders 1502 on both sides receive the PLC signal to extend the cylinders, so that the slide rail connecting block 1511 carrying the gripper cylinder moves down to the lowest point along the mini cylinder push rod 1510. At this time, the bead rod is gripped by the extension and retraction of the two gripper cylinders 1513. After the gripping is completed, the mini cylinder 1502 returns to the starting position. At this point, the sixth motor 1503 starts to rotate, causing the mini cylinder assembly holding the beads, along with its mounting block, to move along the direction of the mold screw 1506. The mold optical axis is responsible for axial positioning. When the bead rod moves to directly above the mold template 1504 (fixed at the bottom or placed on a platform), the mini cylinders on both sides receive PLC signals to retract, causing the slide rail connecting block 1511 carrying the gripper cylinder to move downwards along the mini cylinder push rod 1510 to the lowest point. The release of the bead rod is completed by the extension and retraction of the two gripper cylinders 1513, thus completing the placement of the bead rod. At this point, the brazing filler coating and abrasive coating of the bead rod are completed. The subsequent steps only require vacuum drying and brazing to obtain spiral abrasive beads. Similarly, the bead rope making method is similar to the bead stringing steps.

[0149] Furthermore, the clamping mechanism consists of a pair of left and right arranged gripper cylinders 1513. The PLC sends a signal to control the conduction direction of the two-position three-way solenoid valve to control the clamping and releasing of the gripper cylinders. After the gripper cylinders clamp, the mini cylinder 1502 retracts the air rod and then retracts the gripper through the miniature slide rail. After the gripper cylinders clamp the bead bar, the PLC sends a certain number of pulses to the motor, so that the lead screw can be accurately positioned. Then the gripper cylinders are released to complete the mold loading. After the above actions are completed, the gripper automatically returns to its position to wait for the next bead bar to be loaded.

Claims

1. A spiral beaded string, characterized in that, It consists of fine-diameter beads with an outer diameter of 0.5–20 mm, including a bead base. The outer circumferential surface of the bead base is sequentially provided with an anti-wear ring, a dense spiral zone, a loose spiral zone, and a chip removal ring; wherein, The anti-wear ring and the chip removal ring are both circular ring structures; The spiral dense region and the spiral loose region are respectively provided with a binder spiral coating region to form a spiral structure with a preset pitch; abrasive particles are distributed and fixed on the binder spiral coating region; the abrasive particles and the binder combine to form an abrasive body region, and the binder, abrasive particles and bead matrix in the binder spiral coating region form a metallurgical bond.

2. The spiral beaded string according to claim 1, characterized in that, The spiral density of the dense spiral zone is 5 to 15 spirals per centimeter, and the spiral density of the loose spiral zone is 1 to 10 spirals per centimeter. The number of spirals per centimeter in the dense spiral zone is greater than that in the loose spiral zone. The spiral end of the dense spiral zone is connected to an anti-wear ring. The end of the chip removal ring is 0.5 mm to 5 mm away from the end of the loose spiral zone.

3. A spiral beaded string according to claim 1 or 2, characterized in that, The spirals in the dense and loose spiral regions are distributed with equal or variable pitch. The spirals in the dense and loose spiral regions are either regularly distributed normally or irregularly disordered. In the dense spiral region, the pitch transitions from dense to sparse, while in the loose spiral region, the pitch is regularly distributed normally, gradually increases as a function, or is irregularly disordered.

4. A beaded cord, characterized in that, It includes multiple functional units, each of which includes an anti-wear ring, a spiral dense zone, a spiral loose zone, and a chip removal ring; each functional unit includes one or more beads; the anti-wear ring, spiral dense zone, spiral loose zone, and chip removal ring are simultaneously disposed on the same bead, or separately disposed on multiple beads; the anti-wear ring and the chip removal ring each have at least one annular structure; the spiral dense zone and the spiral loose zone each have a binder spiral coating zone, forming a spiral structure with a preset pitch; abrasive particles are distributed and fixed on the binder spiral coating zone; the binder, abrasive particles, and bead matrix in the binder spiral coating zone form a metallurgical bond.

5. A spiral bead manufacturing device, characterized in that, It includes a continuous feeding assembly, a feed coating assembly, an abrasive coating assembly, and a mold assembly; the continuous feeding assembly, the feed coating assembly, and the abrasive coating assembly are arranged in sequence, and the mold assembly is located on the side of the abrasive coating assembly; The continuous feeding assembly includes a bead rod lifting mechanism and a bead rod transfer mechanism. The bead rod lifting mechanism includes at least two lifting cylinders, each connected to a lifting block for lifting a single bead rod. The lifted bead rod is automatically transferred to the bead rod transfer mechanism. The bead rod transfer mechanism includes a motor-driven feed screw and a slide rail slider that cooperates with the feed screw. The slide rail slider is provided with a semi-conical groove plate, which is used to receive the bead rod transferred from the bead rod lifting mechanism. When the slide rail slider moves, it sends the bead rod on the semi-conical groove plate to the bead rod clamping and rotating mechanism of the feeding coating assembly. The feeding and coating assembly includes a bead rod clamping and rotating mechanism, a bead rod advancing mechanism, and a solder coating mechanism: The bead rod clamping and rotating mechanism includes a rotating clamping cylinder and a three-jaw chuck for clamping and rotating the bead rod; The bead rod advancing mechanism includes a coating feed screw rod and a slide table cooperating with the coating feed screw rod, and the rotating clamping cylinder is located on the slide table; The solder coating mechanism includes a dispensing unit, which cooperates with the bead rod clamping and rotating mechanism and the bead rod advancing mechanism to perform pitch-type coating on the bead rod; The coated bead rod is sent to the bead rod clamping mechanism of the abrasive coating assembly through the operation of the bead rod advancing mechanism; The abrasive coating assembly includes a bead rod clamping mechanism, a vibrating sand falling mechanism, an abrasive recycling mechanism, and a station conversion mechanism; The bead rod clamping mechanism includes a cylinder body and jaws on the cylinder body; The jaws face the incoming material direction to clamp the bead rod sent by the feeding and coating assembly; The vibrating sand falling mechanism includes a bracket erected above the bead rod clamping mechanism; A vibrating screen for abrasive material feeding is connected to the bracket; The abrasive recycling mechanism is located below the vibrating sand falling mechanism; The station conversion mechanism includes a load-carrying bottom plate, and the load-carrying bottom plate cooperates with a station conversion screw rod to achieve lateral movement and move the bead rod under the mold loading assembly; The mold loading assembly includes a pneumatic clamping and picking mechanism and a transfer and mold loading mechanism to pick up and transfer the bead rod coated with abrasive to a preset position.

6. The spiral bead manufacturing equipment according to claim 5, characterized in that, In the continuous feeding assembly, there are two bead placement brackets beside the bead rod lifting mechanism, and the two ends of the bead rod are respectively placed on these two bead placement brackets; There is a bead rod position correction block beside the lifting cylinder; The top of the bead rod position correction block is a slope, which is high on the side close to the bead placement bracket and low on the side close to the semi-conical notch plate, so that the bead rod can automatically roll and transfer to the semi-conical notch plate.

7. The spiral bead manufacturing equipment according to claim 5, characterized in that, In the feeding and coating assembly, the bead rod advancing mechanism further includes two coating optical axes respectively arranged on both sides of the coating feed screw rod; The slide table cooperates with the coating feed screw rod, and both sides of the slide table are respectively slidably arranged on the two coating optical axes and can slide along the coating optical axes; In the feeding and coating assembly, there is also a height adjustment device for adjusting the height of the bead rod.

8. The spiral bead manufacturing equipment according to claim 5, characterized in that, In the abrasive coating assembly, there is a sand falling screw rod on the horizontal rod in the middle of the bracket of the vibrating sand falling mechanism, and a funnel connecting frame is arranged on the sand falling screw rod, and the funnel connecting frame connects the vibrating screen.

9. The spiral bead manufacturing equipment according to claim 5, characterized in that, In the abrasive coating assembly, the upper surface of the load-carrying bottom plate is provided with a transfer screw rod in the left-right direction and a second slide rail arranged parallel to the transfer screw rod, and a third motor drives the transfer screw rod to work; A cylinder mounting plate is arranged on the transfer screw rod, and the cylinder mounting plate can move left and right under the cooperation of the transfer screw rod and the second slide rail; There is an abrasive recycling hopper on the load-carrying bottom plate.

10. A spiral bead manufacturing device according to claim 5, characterized in that, In the mold loading assembly, the transfer and mold loading mechanism includes a transfer bracket, a mold loading screw rod in the front-back direction is arranged in the middle of the transfer bracket, and a mold loading optical axis is respectively arranged in parallel on both sides of the mold loading screw rod, and a "U"-shaped slider cooperating with the mold loading screw rod is arranged on the mold loading screw rod, and both ends of the slider respectively cooperate with the two mold loading optical axes.

11. The spiral bead manufacturing equipment according to claim 10, characterized in that, The pneumatic gripping mechanism includes mini cylinders mounted on each side plate of the slider; a slide rail connecting block is fixed on the mini cylinder push rod of the mini cylinder, and the slide rail connecting block slides in cooperation with the mini slide rail provided on the "U"-shaped side plate, so that when the push rod of the mini cylinder moves, it can drive the slide rail connecting block to move up and down along the mini slide rail; a gripper cylinder is provided on the slide rail connecting block, and the lower end of the gripper cylinder is connected to the gripper. When the gripper cylinder is working, it can control the gripper to open or close, so as to grip or release the bead bar.

12. A method for preparing spiral abrasive beads, using the spiral bead manufacturing equipment according to any one of claims 5 to 11, the method comprising the following steps: (1) Bead rod assembly steps: Place one or more bead bases onto the mandrel to form a bead rod; (2) Continuous feeding step: Multiple bead rods for preparing abrasive beads are placed horizontally on two bead placement brackets of the continuous feeding assembly; a single bead rod is lifted by at least two lifting cylinders and lifting blocks in the bead rod lifting mechanism, so that it automatically rolls down along the inclined surface of the bead rod position correction block and is positioned in the semi-conical slot plate of the bead rod transfer mechanism; then, the feed screw driven by the motor drives the slide rail slider to transfer the bead rod at a constant speed to the feed coating assembly; (3) Spiral coating step: The bead bar clamping and rotating mechanism of the feeding coating assembly clamps one end of the bead bar through a rotating clamping cylinder and a three-jaw chuck, and drives the bead bar to rotate at a constant speed around the axis of the bead bar; at the same time, the bead bar forward mechanism drives the slide table to feed along the coating optical axis through the coating feed screw, so that the bead bar keeps moving forward; the dispensing unit of the solder coating mechanism, under the control of PLC, synchronously performs quantitative extrusion and re-suction of solder according to the preset pulse frequency, and forms a spiral solder layer on the surface of the bead bar by coordinating the rotation speed of the bead bar and the axial feed speed. The pitch of the spiral can be controlled and adjusted by changing the feed speed, and the coating mode includes constant pitch or variable pitch. (4) Abrasive coating step: The beaded rod coated with brazing filler metal is fed into the abrasive coating assembly by the feeding coating assembly. The beaded rod is held by the cylinder and jaws of the beaded rod clamping mechanism, and the beaded rod is driven to the coating station by the flip drive motor. The vibrating sand removal mechanism moves at a constant speed along the axial direction of the beaded rod by the sand removal screw through the vibrating screen. At the same time, the vibration generator makes the abrasive particles fall evenly and adhere to the surface of the brazing filler metal. The abrasive particles that do not adhere fall into the abrasive particle recycling hopper for recycling and reuse. (5) Mold transfer step: After the abrasive coating is completed, the station conversion mechanism moves the bead bar laterally to the bottom of the mold assembly through the cooperation of the base plate and the station conversion screw; the pneumatic clamping mechanism of the mold assembly pushes the slide rail connecting block down along the mini slide rail through the mini cylinder, the gripper cylinder clamps the bead bar and lifts it up, and the transfer mold assembly mechanism drives the bead bar to the preset position of the mold template through the mold assembly screw for placement; (6) Post-processing steps: Vacuum brazing is performed on the entire coated bead rod to allow the brazing filler metal to climb up and wrap around the root of the abrasive grains to form a strong bond; finally, the processed beads are removed from the bead rod one by one to obtain spiral abrasive beads; or they are removed and cut and separated again to obtain spiral abrasive beads.

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