A sawing machine discharge end intelligent buffering, detecting, sorting and maintaining system and conveying method

Abstract

The application discloses a sawing machine discharging end intelligent buffering, detecting, sorting and maintaining system and a conveying method, and belongs to the technical field of automatic conveying. The system comprises a discharging conveying line, a buffering conveying line, a detecting device, a waste conveying line, a waste collecting device and an electric control system which are sequentially arranged along a working procedure and cooperatively work. The electric control system is configured to control the diversion and transfer of workpieces and waste, and to perform predictive maintenance, record whole-process data and optimize core parameters and maintenance decision logic through self-learning. The application realizes closed-loop intelligent management and control from online detection and sorting to predictive maintenance, and significantly improves product quality, production efficiency and equipment management level.

Description

Technical Field

[0001] This invention relates to the field of automated conveying technology, and in particular to an intelligent buffering, detection, sorting and maintenance system and conveying method for the output end of a sawing machine. Background Technology

[0002] In the metal processing industry, sawing machines are key equipment for cutting bars and tubes. Currently, the cutting process of most sawing machines still relies on manual or semi-automatic methods, mainly due to the following technical bottlenecks: The inspection process is often incomplete or outdated: the quality of cut workpieces (such as length tolerance, end face perpendicularity, cut surface quality, and workpiece weight) largely depends on post-cut sampling or manual visual inspection, which is inefficient and prone to omissions. Although there are solutions using a single sensor (such as a metal induction sensor) for end-point inspection, the detection distance varies greatly when the workpiece is small, curved, or has warped end faces, resulting in unreliable results. These inspection functions are often independent of the loading and unloading process, making control complex and difficult to integrate with the sawing machine and subsequent processes, leading to low overall production efficiency.

[0003] The production line application has a slow cycle time: Because the saw cuts the head and tail of the raw material during cutting, many ineffective cuts will occur in the continuous production line, which will slow down the production cycle time of the entire line. The time interval for a single saw to perform continuous effective cuts is T. However, when the head and tail of the raw material are connected, the saw will perform two more cuts. When the saw finishes processing the tail of the previous raw material and starts processing the head of the next new raw material, it needs to perform three consecutive cutting operations, with a total time consumption of 3T. Therefore, the cycle time of the entire production line will be greater than 3T in order to meet the requirements of continuous production.

[0004] Lack of process data and intelligent management: Traditional material cutting processes lack real-time collection and analysis of workpiece quality parameters and equipment status data. Operators cannot understand the trend of sawing quality in real time (such as the gradual change in cut quality due to saw blade wear), nor can they achieve data-driven predictive maintenance, such as providing early warning and replacement before the saw blade reaches its life limit, thereby avoiding the generation of batch scrap and unexpected equipment downtime. Summary of the Invention

[0005] To address the problems mentioned above, this invention provides an intelligent buffering, detection, sorting, and maintenance system and conveying method for the output end of a sawing machine. The aim is to achieve fully automated online detection of cut workpieces, intelligent sorting and flexible buffering based on the detection results, and to integrate data acquisition and lifespan prediction functions, thereby improving the automation level of the cutting process, product quality consistency, and the level of intelligent production management.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A smart buffering, detection, sorting and maintenance system for the discharge end of a sawing machine includes a sawing machine, and the discharge end of the sawing machine is connected to a discharge conveying device, which includes: The discharge conveyor line is set at the discharge end of the saw and is used to receive and transport the cut workpieces and waste materials. A buffer conveyor line, located adjacent to the discharge conveyor line, is used to receive and buffer workpieces from the discharge conveyor line. The detection device is installed at the end of the buffer conveyor line to detect the workpieces coming from the buffer conveyor line and output quality parameters. The reject conveyor line is connected to the end of the inspection device and is used to transport the inspected workpieces; Waste collection device: used to collect waste materials and defective workpieces; The electrical control system is connected to the discharge conveyor line, buffer conveyor line, detection device and waste rejection conveyor line respectively. The maintenance system, integrated into the electrical control system, is used to predict the maintenance needs of the saw blades of the sawing machine. The electronic control system is configured as follows: Control the diversion and transfer of workpieces and waste materials on the discharge conveyor line; Control the rhythm of the buffer conveyor line feeding workpieces to the detection device; The waste removal conveyor line is controlled to perform sorting based on the quality parameters of the detection device.

[0007] Furthermore, the discharge conveyor line includes a first chain conveyor line, a pushing module, and a distributing module. The pushing module is located on one side of the discharge conveyor line, and the output end of the pushing module corresponds to the buffer conveyor line. The material distribution module includes a baffle lifting cylinder and a material distribution baffle. The baffle lifting cylinder is fixedly connected to the downstream side of the discharge conveyor line. The output end of the baffle lifting cylinder is connected to one end of the material distribution baffle. A baffle mounting frame is provided on the first chain conveyor line. The material distribution baffle is slidably connected to the baffle mounting frame. A waste material conveying port is also connected to the end of the discharge conveyor line.

[0008] Furthermore, the buffer conveyor line is a chain conveyor line, and a buffer limit baffle is provided at the lower end of the buffer conveyor line; The buffer conveyor line's conveying direction is perpendicular to the discharge conveyor line; The discharge conveyor line, buffer conveyor line, and detection device are fixed on the upper plane of the first frame, while the waste rejection conveyor line and electrical control system are set on the second frame.

[0009] Furthermore, the detection device includes a pusher cylinder mounting bracket, which is fixed to one end of the first frame. The top of the pusher cylinder mounting bracket is higher than the first frame. A detection pusher cylinder is mounted on the pusher cylinder mounting bracket. A detection pusher plate is mounted on the output end of the detection pusher cylinder. A detection camera is set on the end of the detection pusher plate near the discharge conveyor line. The running direction of the detection pusher cylinder is perpendicular to the conveying direction of the buffer conveyor line.

[0010] Furthermore, the detection device also includes a weighing device, which is located below the detection pusher cylinder and includes a weighing support platform. A weighing lifting cylinder is installed above the weighing support platform. A weighing sensor is connected to the output end of the weighing lifting cylinder. A weighing support frame is installed on top of the weighing sensor, and multiple support claws are installed on top of the weighing support frame.

[0011] Furthermore, the weighing device also includes a roller conveyor mechanism, which includes a detection conveyor motor, a drive roller, and multiple driven rollers. The drive roller and multiple driven rollers are arranged at intervals along the conveying direction. The two ends of the conveyor rollers are rotatably supported on the guard plate by bearings, and the guard plate is fixedly installed on the upper surface of the first frame. The output gear of the detection conveyor motor is connected to a first sprocket, which meshes with a drive gear. The drive gear is sleeved on one end of the drive drum, which meshes with a second sprocket. The second sprocket meshes with one end of multiple driven drums. Multiple support claws shuttle between the roller conveyor mechanisms; The end of the roller conveyor mechanism is also equipped with a length measuring baffle, and the bottom end of the length measuring baffle is connected to the output end of the length measuring baffle lifting cylinder.

[0012] Furthermore, the waste removal conveyor line includes a third chain conveyor line and a waste removal baffle. The waste removal baffle spans the third chain conveyor line and is slidably connected to the waste removal baffle mounting frame. One end of the waste removal baffle is connected to the output end of the waste removal lifting cylinder. The third chain conveyor line is equipped with a waste removal push plate and a waste removal outlet on both sides, with the waste removal push plate located in front of the waste removal baffle. Behind the rejecting baffle, there is also a qualified product baffle. The qualified product baffle spans across the top of the third chain conveyor line. There are also corresponding qualified product push plates and qualified product outlets between the rejecting baffle and the qualified product baffle, and they are respectively set on both sides of the rejecting conveyor line. The reject pusher pushes out unqualified workpieces from the reject exit, and the qualified product pusher pushes out qualified workpieces from the qualified product exit. The waste export and qualified product export are both exported via a cylindrical guide rod array.

[0013] Furthermore, the discharge conveyor line and the rejection conveyor line respectively guide the waste and unqualified workpieces to the waste collection device.

[0014] Furthermore, the maintenance system is configured as follows: Obtain at least two independent quality parameters related to saw blade wear, as monitored by the detection device, including workpiece dimensional parameters and / or cross-sectional parameters; The quality parameters are normalized and weighted according to predetermined rules to calculate the comprehensive deterioration index. The overall degradation index is compared with a dynamic threshold, which is adaptively adjusted according to the type of material being processed and / or the feed rate of the saw. Maintenance decisions are made based on preset maintenance decision logic. When the comprehensive deterioration index continues to exceed the dynamic threshold, it is determined that the saw blade needs maintenance and a maintenance signal is triggered. Record a complete data chain that includes quality parameters, overall degradation index, trend analysis results, and maintenance decisions; Analyze the complete data chain to adaptively optimize the weights of each quality parameter, the calculation parameters of dynamic thresholds, or maintain decision logic.

[0015] Furthermore, a conveying method employing the aforementioned intelligent buffering, detection, sorting, and maintenance system at the output end of a sawing machine includes the following steps: S1: Workpieces and scrap are output from the sawing machine; workpieces and scrap are identified. S2: If it is a workpiece, the material distribution baffle remains in place to block the workpiece, and the pushing module pushes the workpiece into the buffer conveyor line; S3: If it is waste material, the material distribution baffle slides upward, and the waste material continues to flow along the discharge conveyor line from below the material distribution baffle until it flows out from the waste material conveyor into the waste material collection device; S4: The workpiece enters the buffer conveyor line for buffering, and then flows into the detection device for detection; S5: The detection pusher cylinder pushes the workpiece into the detection device, the length measuring baffle extends, and at the same time, the detection camera takes pictures of the cross-section of the workpiece to detect its cross-sectional quality. When the detection pusher pushes the workpiece to contact the length measuring baffle, the pushing stops. Based on the stroke of the detection pusher cylinder, it is determined whether the length of the workpiece is qualified. S6: Detects the retraction of the pusher cylinder and the length measuring baffle, and detects the ejection of the lifting cylinder to remove the workpiece from the support of the roller conveyor mechanism. The weighing sensor measures the weight of the workpiece and determines whether the weight is qualified. S7: After inspection, the workpiece is transferred to the rejection conveyor line; S8: If qualified, the workpiece is pushed out from the qualified product exit. S9: If the workpiece is not qualified, the rejection baffle will descend to intercept it, and the rejection pusher will push the workpiece from the rejection outlet to the waste collection device. S10: During the workpiece inspection process, the maintenance system predicts the maintenance needs of the saw blade of the banding machine.

[0016] The advantages of this invention are: 1. By designing the discharge conveyor line and the buffer conveyor line, and the buffer conveyor line and the detection device in a compact layout that is vertically connected, this invention greatly reduces the overall footprint of the system while ensuring a smooth process flow, reduces the user's requirements for factory space, improves space utilization, and makes the equipment layout more regular and the logistics clearer. 2. Achieve zero waste flow: Through online detection and real-time sorting, ensure that unqualified workpieces, material heads, and material tails are automatically rejected to prevent them from flowing into downstream processes, thus ensuring the consistency of product batch quality from the source; 3. Maximize equipment utilization: Through predictive maintenance, saw blade replacement / sharpening is transformed from "planned downtime" or "fault downtime" into a predictable and plannable short window. Combined with intelligent adjustment of production rhythm, unplanned downtime is significantly reduced, and the continuous operation capability of the production line is improved. 4. Possesses self-learning and self-optimization capabilities: By recording the complete data chain of the entire process and using historical data to continuously optimize model parameters (such as fusion weights, dynamic thresholds, counting rules in decision logic, etc.), the prediction and decision-making capabilities of the maintenance system are continuously improved during use, possessing long-term adaptability and vitality. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall layout structure of the present invention; Figure 2 This is a schematic diagram of the material discharge conveyor line, buffer conveyor line, and detection device of the present invention; Figure 3 This is a cross-sectional schematic diagram of the detection device of the present invention; Figure 4 This is a schematic diagram of the waste removal conveyor structure of the present invention; Figure 5 This is a schematic diagram of the framework of the present invention; Figure 6 This is a schematic diagram of the maintenance system workflow of the present invention; Figure 7 This is a schematic diagram of the workflow of the present invention.

[0018] In the diagram: 1. Sawing machine; 2. Discharge conveyor line; 201. Pushing module; 202. Baffle lifting cylinder; 203. Distributing baffle; 204. Waste material conveying port. 3. Buffer conveyor line, 301. Buffer limit baffle. 4. Detection device 401. Inspect the pusher cylinder; 402. Inspect the camera; 403. Inspect the pusher plate; 404. Inspect the weighing lifting cylinder. 405. Load cell; 406. Weighing support frame; 407. Conveyor roller; 408. Length measuring baffle. 409. Measuring baffle lifting cylinder; 410. Pushing cylinder mounting bracket; 411. Inspection conveyor motor. 5. Waste removal conveyor line, 501. Scrap removal baffle; 502. Scrap removal lifting cylinder; 503. Scrap removal pusher plate; 504. Scrap removal outlet; 505. Qualified product baffle; 506. Qualified product pusher plate; 507. Qualified product outlet. 6. Human-machine interface; 7. Electrical control system; 8. Waste collection device; 9. Workpiece; 10. First frame; 11. Second frame; 12. Maintenance system; 120. Data acquisition module; 121. Data processing module; 122. Trend analysis module; 123. Maintenance prediction module; 124. Self-learning module. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1, please refer to Figures 1-4 A smart buffering, detection, sorting and maintenance system for the discharge end of a sawing machine includes a sawing machine 1, with a discharge conveying device connected to the discharge end of the sawing machine 1. The discharge conveying device includes: The discharge conveyor line 2 is set at the discharge end of the saw 1 and is used to receive and convey the cut workpiece 9 and waste material; The buffer conveyor line 3 is arranged adjacent to the discharge conveyor line 2 and is used to receive and buffer the workpiece 9 from the discharge conveyor line 2; The detection device 4 is set at the end of the buffer conveyor line 3 and is used to detect the workpiece 9 from the buffer conveyor line 3 and output quality parameters. The reject conveyor line 5 is connected to the testing device 4 and is used to convey the tested workpieces 9. The electrical control system 7 is communicatively connected to the discharge conveyor line 2, the buffer conveyor line 3, the detection device 4, and the waste rejection conveyor line 5, respectively. Maintenance system 12, which is integrated into the electrical control system 7, is used to predict the maintenance needs of the saw blade of the sawing machine 1; The electronic control system 7 is configured as follows: Control the diversion and transfer of workpiece 9 and waste material on the discharge conveyor line 2; Control the rhythm of conveying workpiece 9 from buffer conveyor line 3 to detection device 4; The waste removal conveyor line 5 is controlled to perform sorting based on the quality parameters of the detection device 4.

[0021] The discharge conveyor line 2, the buffer conveyor line 3 and the detection device 4 are fixed on the upper plane of the first frame 10, and the waste removal conveyor line 5 and the electrical control system 7 are set on the second frame 11.

[0022] Both the first frame 10 and the second frame 11 are integral rigid frames welded from heavy-duty rectangular steel pipes. Their upper surfaces are precision machined and serve as the installation reference surfaces for the discharge conveyor line 2, the buffer conveyor line 3, the detection device 4, and the waste rejection conveyor line 5.

[0023] The first frame 10 serves as the upstream conveying platform, on which the discharge conveyor line 2, the buffer conveyor line 3, and the detection device 4 are integrated and fixed, ensuring the relative positional accuracy between the three core functional units of sawing, conveying, and detection, and effectively reducing measurement errors caused by vibration or deformation.

[0024] The second rack 11 serves as the downstream conveying and control platform, independently supporting the waste removal conveyor line 5 and the electrical control system 7. This layout achieves physical isolation between upstream and downstream conveying, facilitating wiring, maintenance, and heat dissipation.

[0025] The first frame 10 and the second frame 11 are reliably fixed to the installation ground by positioning pins and high-strength bolts, together forming a well-structured, rigid, and highly modular equipment foundation.

[0026] Through the above technical solution, after the workpiece 9 cut from the sawing machine 1 is output from the sawing machine 1, it passes through the discharge conveyor line 2. A first sensor is installed at the front end of the discharge conveyor line 2 to detect whether it is workpiece 9. If it is workpiece 9, it continues to be conveyed to the buffer conveyor line 3. When it is necessary to detect the length and cross-sectional quality of workpiece 9, workpiece 9 is conveyed to the detection device 4. After workpiece 9 has been detected by the detection device 4, it passes through the rejection conveyor line 5 to sort out unqualified workpiece 9 and qualified workpiece 9, so that qualified workpiece 9 flows to the next process.

[0027] In this embodiment, the sawing machine 1 adopts existing technology and can perform automated cutting. The sawing machine 1 includes a saw blade for performing the cutting. During continuous cutting, the saw blade will gradually wear down, which directly manifests as a decrease in the dimensional accuracy of the cut workpiece 9 and a deterioration in the quality of the cut surface. The present invention monitors these workpiece quality parameters in real time through the detection device 4. The maintenance system 12 can indirectly assess and predict the wear state of the saw blade by analyzing the deterioration trend of these quality parameters, thereby achieving predictive maintenance.

[0028] Example 2, based on the above examples, continues to refer to... Figure 1 and Figure 2The discharge conveyor line 2 includes a first chain conveyor line, a pushing module 201 and a distributing module. The pushing module 201 is located on one side of the discharge conveyor line 2, and the output end of the pushing module 201 corresponds to the buffer conveyor line 3. In this embodiment, the first chain conveyor line is used to directly bear and transport the workpiece 9. First guard plates are provided on both sides of the first chain conveyor line to protect the workpiece 9 from falling. A discharge conveyor motor is installed on the first frame 10. The conveying end of the discharge conveyor motor meshes with one end of the discharge conveyor chain, and the other end of the discharge conveyor chain meshes with a discharge conveyor driven gear. The discharge conveyor driven gear is sleeved on the discharge conveyor main shaft. The discharge conveyor main shaft is then mounted on one end of the first guard plate through bearings. The discharge conveyor main shaft is sleeved with multiple discharge conveyor three-row sprockets. The other end of the first guard plate is rotatably provided with a discharge conveyor driven shaft, which is sleeved with the same discharge conveyor three-row sprockets. The discharge conveyor three-row sprockets at both ends mesh with the first chain conveyor line. In this way, when the discharge conveyor motor rotates, it drives the discharge conveyor main shaft to rotate, which in turn drives the multiple discharge conveyor three-row sprockets to rotate. The rotation of the discharge conveyor three-row sprockets ultimately drives the first chain conveyor line to rotate, thereby transporting the workpiece 9 on the first chain conveyor line.

[0029] To ensure the load-bearing capacity of the first chain conveyor line, a support platform is installed at the bottom of the first chain conveyor line, with both sides of the support platform fixed to the first guard plate. Chain guide rails are also installed on the support platform to guide the first chain conveyor line.

[0030] To separate and transfer workpiece 9 from waste material on the discharge conveyor line 2, a pusher module 201 is provided on one side of the discharge conveyor line 2. A first notch for the operation of the pusher module 201 is provided on the first guard plate. The pusher module 201 includes a pusher mounting plate, which is mounted on the first frame 10. A pusher cylinder and two guide plates are fixedly mounted on the pusher mounting plate. The two guide plates are located on both sides of the pusher cylinder. The pusher plate is fixed together at the output end of the pusher cylinder and the front end of the two guide plates. The pusher plate is used to push workpiece 9 into the buffer conveyor line 3.

[0031] To divert and transfer waste material to the end of the discharge conveyor line 2, a material distribution module is provided on one side of the pushing module 201. To ensure the continuity of the cycle, the material distribution module and the pushing module 201 are arranged adjacent to each other. The material distribution module includes a baffle lifting cylinder 202 and a material distribution baffle 203. The baffle lifting cylinder 202 is fixedly connected to the downstream side of the discharge conveyor line 2. The output end of the baffle lifting cylinder 202 is connected to one end of the material distribution baffle 203. The material distribution baffle 203 is slidably connected to the baffle mounting frame. Specifically, slide rails are fixedly installed on both sides of the baffle mounting frame, and sliders slide on the slide rails respectively. The material distribution baffle 203 is fixedly connected to the sliders. The baffle mounting frame is fixed to the first guard plate. When the output end of the baffle lifting cylinder 202 outputs, the material distribution baffle 203 will slide on the baffle mounting frame. The end of the discharge conveyor line 2 is also connected to a waste material conveying port 204.

[0032] When the first sensor identifies the workpiece 9, the material distribution baffle 203 remains stationary and blocks the workpiece 9. At the same time, the pusher module 201 receives a signal and drives the pusher plate to push the workpiece 9 into the buffer conveyor line 3.

[0033] When the first sensor identifies it as waste material, in this embodiment the waste material consists of the head and tail of the material. The output of the baffle lifting cylinder 202 is output, which drives the material distribution baffle 203 to leave the horizontal plane of the first chain conveyor line, and the waste material is then conveyed to the waste material conveying port 204.

[0034] Example 3: Based on the above examples, continue to refer to... Figure 1 and Figure 3 The buffer conveyor line 3 is a chain conveyor line, and a buffer limiting baffle 301 is provided at the lower end of the buffer conveyor line 3. In this embodiment, the buffer conveyor line 3 is located between the discharge conveyor line 2 and the detection device 4, and serves as a buffer that can dynamically store multiple workpieces 9. When the detection device 4 is in a working cycle, the workpieces 9 conveyed by the discharge conveyor line 2 can be temporarily stored here, avoiding the sawing machine 1 being forced to stop due to downstream blockage.

[0035] Through the coordinated action of the buffer limit baffle 301 at its lower end, the buffer conveyor line 3 can form an orderly queue of temporarily stored workpieces 9 and transport workpieces 9 one by one and at intervals according to the processing capacity of the detection device 4, ensuring that the detection device 4 processes only one workpiece 9 at a time, thus creating conditions for accurate detection.

[0036] The buffer conveyor line 3 effectively solves the problem of mismatch between the continuous output of the sawing machine 1 and the downstream detection and sorting processes, ensuring the continuity, stability and efficiency of the entire system process.

[0037] The buffer conveyor line 3 is perpendicular to the discharge conveyor line 2, and the two lines adopt a perpendicular turning layout. This design breaks away from the traditional straight-line layout, allowing the equipment to occupy a more compact area within the factory floor plan, rather than a long and narrow passage, significantly saving valuable production workshop floor space. It also spatially separates the buffer conveyor line 3 and the discharge conveyor line 2, providing operators with a clearer work area.

[0038] The length of the buffer conveyor line 3 can be set according to actual needs. Due to the function of the buffer conveyor line 3, the cycle time of the sawing production line can be adjusted from greater than 3T as described in the technical background to greater than T but less than 3T, thereby improving the overall cycle time of the sawing production line.

[0039] Example 4, continue to refer to Figure 1 , Figure 2 and Figure 3 In order to inspect workpiece 9, an inspection device 4 is set at the end of the buffer conveyor line 3. The inspection device 4 includes a pusher cylinder mounting frame 410, which is fixed to one end of the first frame 10. The top of the pusher cylinder mounting frame 410 is higher than the first frame 10. An inspection pusher cylinder 401 is installed on the pusher cylinder mounting frame 410. An inspection pusher plate 403 is installed at the output end of the inspection pusher cylinder 401. An inspection camera 402 is set at one end of the inspection pusher plate 403 near the discharge conveyor line 2. The running direction of the inspection pusher cylinder 401 is perpendicular to the conveying direction of the buffer conveyor line 3.

[0040] In this embodiment, the detection pusher cylinder 401 is a rodless cylinder. A rodless cylinder is a type of cylinder that transmits the linear motion of a piston to an external slider through magnetic or mechanical coupling, thus eliminating the need for a piston rod extending out of the cylinder body. Its core value lies in achieving long-stroke linear motion with minimal installation space. When detection is required, a detection pusher plate 403 is installed on the slider of the detection pusher cylinder 401. The initial position of the detection pusher plate 403 is located at... Figure 3 At the right end, when testing is required, the testing pusher cylinder 401 moves to the left, which drives the testing pusher plate 403 to move to the left, and the testing pusher plate 403 pushes a workpiece 9 to move to the left.

[0041] The detection device 4 also includes a weighing device, which is located below the detection pusher cylinder 401 and includes a weighing support platform. A weighing lifting cylinder 404 is provided above the weighing support platform. A weighing sensor 405 is connected to the output end of the weighing lifting cylinder 404. A weighing support frame 406 is provided on the top of the weighing sensor 405. Multiple support claws are provided on the top of the weighing support frame 406. The weighing device also includes a roller conveyor mechanism, which includes a detection conveyor motor 411, a drive roller 407 and multiple driven rollers. The drive roller 407 and multiple driven rollers are arranged at intervals along the conveying direction. The two ends of the conveyor roller 407 are rotatably supported on the guard plate by bearings. The guard plate is fixedly installed on the upper surface of the first frame 10. The output gear of the detection conveyor motor 411 is connected to a first sprocket. The first sprocket meshes with a drive gear. The drive gear is sleeved on one end of the drive roller 407. The drive gear meshes with a second sprocket. The second sprocket meshes with one end of multiple driven rollers. Multiple support claws shuttle between the roller conveyor mechanisms; The end of the roller conveyor mechanism is also equipped with a length measuring baffle 408, and the bottom end of the length measuring baffle 408 is connected to the output end of the length measuring baffle lifting cylinder 409.

[0042] While workpiece 9 is being conveyed to the left, the detection camera 402 takes a picture of workpiece 9 to detect its cross-sectional quality. At the same time, the length measuring baffle 408 extends upward under the action of the length measuring baffle lifting cylinder 409, blocking the continued movement of workpiece 9. The detection push plate 403 pushes workpiece 9 onto the roller conveyor until the front end of workpiece 9 contacts the length measuring baffle 408. The length of workpiece 9 is calculated by the stroke of the detection push cylinder 401.

[0043] After the length of workpiece 9 is detected, the detection push plate 403 and the length measuring baffle 408 retract, and the electronic control system 7 controls the weighing lifting cylinder 404 to push out, which drives the weighing sensor 405 and the weighing support frame 406 to push upward. Multiple support claws set on the weighing support frame 406 pass through the active roller 407 and multiple driven rollers, finally causing workpiece 9 to be removed from the support of the roller conveying mechanism, so that the weight of workpiece 9 can be measured by the weighing sensor 405.

[0044] After the workpiece 9 has been inspected, it will be transported to the rejection conveyor line 5 by the roller conveyor mechanism. Specifically, the inspection conveyor motor 411 rotates, which drives the first sprocket to rotate. The first sprocket then drives the second sprocket to rotate, which in turn drives the entire roller conveyor mechanism to rotate, thereby transporting the workpiece 9 forward.

[0045] Example 5, refer to Figure 1 and Figure 4 In order to sort qualified workpieces 9 and unqualified workpieces 9, a rejection conveyor line 5 is set at the end of the detection device 4, including a third chain conveyor line and a rejection baffle 501. The rejection baffle 501 spans the third chain conveyor line and is slidably connected to the rejection baffle mounting frame. One end of the rejection baffle 501 is connected to the output end of the rejection lifting cylinder 502. The third chain conveyor line is equipped with a waste removal push plate 503 and a waste removal outlet 504 on both sides, with the waste removal push plate 503 located upstream of the waste removal baffle 501. Downstream of the rejecting baffle 501, a qualified product baffle 505 is also provided. The qualified product baffle 505 spans across the third chain conveyor line. Between the rejecting baffle 501 and the qualified product baffle 505, there are also corresponding qualified product push plates 506 and qualified product outlets 507, which are respectively located on both sides of the third chain conveyor line. Similarly, third guard plates are provided on both sides of the third chain conveyor line. The third guard plates have notches at the corresponding positions of the scrap push plate 503, scrap outlet 504, qualified product push plate 506, and qualified product outlet 507, so that the scrap push plate 503 pushes out the unqualified workpiece 9 from the scrap outlet 504, and the qualified product push plate 506 pushes out the unqualified workpiece 9 from the qualified product outlet 507. The scrap baffle mounting bracket and the scrap lifting cylinder 502 are fixedly installed on the third guard plate.

[0046] The initial position of the scrap removal lifting cylinder 502 is ejection, which facilitates the continuous conveying of qualified workpieces 9. Only when the detection device 4 detects that the workpiece 9 is unqualified, the output end of the scrap removal lifting cylinder 502 descends to block the unqualified workpiece 9, and the output end of the scrap removal push plate 503 ejects, pushing the unqualified workpiece 9 out of the scrap removal outlet 504.

[0047] In this embodiment, the reject pusher plate 503 and the qualified product pusher plate 506 have the same structure and are both pushed out after being connected to the cylinder output end.

[0048] The reject outlet 504 and the qualified product outlet 507 are cylindrical guide rod array outlets. The contact between the cylindrical guide rod array outlet and the workpiece 9 is a line contact, which reduces the contact area and allows the workpiece 9 to slide out more smoothly.

[0049] The detection device 4 can determine whether the workpiece 9 is a qualified product. When the workpiece 9 is a qualified product, the electrical control system 7 controls the output end of the scrap removal lifting cylinder 502 to push out the qualified workpiece 9. The qualified workpiece 9 continues to be conveyed forward. The qualified product baffle 505 is equipped with a positioning detection sensor. When the qualified workpiece 9 contacts the qualified product baffle 506, the electrical control system 7 controls the cylinder behind the qualified product push plate 505 to push out the qualified workpiece 9 from the qualified product outlet 507.

[0050] Example 6: The discharge conveying device also includes a waste collection device 8. The discharge conveying line 2 and the rejection conveying line 5 can respectively guide waste and unqualified workpieces 9 to the waste collection device 8.

[0051] In this embodiment, the waste collection device 8 is as follows: Figure 1As shown, the waste collection device 8 is equipped with rollers at its bottom, allowing for flexible movement, and is positioned below both the waste conveying port 204 and the rejecting outlet 504. Compared to configuring separate collection containers for the two outlets, this embodiment saves valuable working space next to the equipment, resulting in a more compact and tidy layout. It allows for the centralized collection and unified processing of sawing head and tail materials, as well as rejected workpieces 9, optimizing the spatial layout and greatly facilitating the waste removal process.

[0052] Example 7, as Figure 5 As shown, in order to perform predictive maintenance on the saw blade in the sawing machine, a maintenance system 12 is integrated into the electrical control system 7. The maintenance system 12 is configured as follows: Acquire at least two independent quality parameters related to saw blade wear, monitored by detection device 4, including dimensional parameters or cross-sectional parameters; The quality parameters are normalized and weighted according to predetermined rules to calculate the comprehensive deterioration index. The overall deterioration index is compared with a dynamic threshold, which is adaptively adjusted according to the type of material being processed and / or the feed rate of the saw 1. According to the preset maintenance decision logic, when the comprehensive deterioration index continues to exceed the dynamic threshold, it is determined that the saw blade needs maintenance and a maintenance signal is triggered. Record a complete data chain that includes quality parameters, overall degradation index, trend analysis results, and maintenance decisions; Analyze the complete data chain to adaptively optimize the weights of each quality parameter, the calculation parameters of dynamic thresholds, or maintain decision logic.

[0053] Maintenance system 12 is connected to the workshop maintenance management system.

[0054] The maintenance system 12 logically comprises the following functional modules connected in sequence: data acquisition module 120, data processing module 121, trend analysis module 122, and maintenance prediction module 123. Each module is configured to call and run the corresponding preset models and rules.

[0055] These preset models and rules, when the maintenance system 12 is first enabled or reset, specifically include the following core configurations: Dynamic threshold model: This model dynamically calculates the current dynamic threshold T based on the current processing conditions. The dynamic threshold T is a benchmark value used to determine whether the current workpiece 9 has deteriorated beyond the limit. Its value is dynamically adjusted according to the current processing conditions to eliminate the influence of changes in material hardness and feed rate on workpiece quality judgment, making the judgment result more accurately reflect the wear state of the saw blade itself. The specific calculation method is as follows: Base threshold T base =75 (corresponding to standard processing conditions).

[0056] The current dynamic threshold T is calculated using the formula: T = T base ×k m ×k v .

[0057] Among them, the material adjustment coefficient k m =1-α×(HB-HB base (HB represents the current material hardness, HB) base =200 is the reference hardness, and α=0.005 is the influence coefficient). Speed ​​adjustment coefficient k v =v0 / v (v is the current feed rate, v0=50mm / s is the reference feed rate).

[0058] Quality parameter standard values, judgment thresholds, and data fusion rules: This section outlines the quality parameters used to calculate the Comprehensive Deterioration Index (CDI), including the standards and thresholds for each parameter, and the data fusion rules. In this embodiment, the following two quality parameters are used as the basis for calculating the CDI: Length deviation (ΔL): The difference between the actual length of workpiece 9 and the reference length; Average burr height (H): The statistical average of the burr height on the cut end face of workpiece 9.

[0059] The standard values ​​and judgment thresholds for each quality parameter are defined as follows: Length deviation (ΔL) setting: The standard value is ΔL ≤ 0.1mm (i.e., ΔL not exceeding 0.1mm is considered acceptable). The warning threshold is ΔL = 0.15mm, and the extreme threshold is ΔL = 0.5mm. The average burr height (H) is set as follows: the standard value is 0.5-1.5mm (i.e., H is acceptable within this range), the warning threshold is 1.6-2.0mm, and the extreme threshold is >2.0mm.

[0060] Data fusion rules: After normalizing the above quality parameters, the Comprehensive Deterioration Index (CDI) is calculated by weighting and fusion according to the following weights: Fusion weight: Length deviation weight W L =0.6, weight of average burr height W H =0.4 (W) L +W H =1); Calculation formula: CDI = W L ×I L +W H ×I H , where I L I H These are the normalized exponents for length deviation and average burr height, respectively.

[0061] Maintenance decision logic: It is used to determine whether to trigger a maintenance signal based on the comparison result of the comprehensive degradation index (CDI) and the current dynamic threshold. The specific rule is: the maintenance signal is triggered when the comprehensive degradation index (CDI) of 7 out of 10 consecutive workpieces 9 exceeds the current dynamic threshold T.

[0062] Degradation Trend Analysis Model: Used to analyze the changing trend of the Comprehensive Degradation Index (CDI) time series. It is based on a linear regression algorithm to calculate the slope of the CDI time series to determine the degradation rate.

[0063] Historical Database: To enable self-learning and lifespan prediction, the historical database is configured to store and associate the following two core data types based on saw blade usage cycles: 1. Process data recording During the operation of the maintenance system 12, the quality parameters, comprehensive degradation index (CDI), key trend characteristics and maintenance signals corresponding to each workpiece 9 are stored in a structured manner according to the timestamp and workpiece serial number in real time. 2. Construction of the entire life cycle degradation curve Each time a saw blade completes its service life, the maintenance system 12 automatically extracts and arranges the Comprehensive Deterioration Index (CDI) for all workpieces 9 within that cycle, according to the processing sequence (workpiece serial number), forming a historical CDI time-series sequence for that saw blade. Based on this historical CDI time-series sequence, a complete curve is directly constructed with the workpiece serial number as the x-axis and the corresponding CDI value as the y-axis, representing the entire lifecycle deterioration curve. This curve is then bound and stored with the following metadata: The saw blade identification information (such as batch number); Main processing conditions (such as statistical distribution of processed material types, average feed rate); Life end definition (i.e., the specific conditions for triggering this maintenance and the actual maintenance signal).

[0064] Life prediction model: used to predict the remaining usable life of the current saw blade. The method is as follows: by comparing the real-time CDI time series of the current saw blade with the full life cycle degradation curve in the historical database, and taking into account the current processing material and feed rate, the remaining usable life of the saw blade (such as the number of remaining workpieces or the estimated time) is calculated.

[0065] When the system is running, the modules work together, such as Figure 6 As shown, the process is as follows: P1: Quality Parameter Acquisition. The data acquisition module 120 acquires in real-time at least two independent quality parameters strongly correlated with saw blade wear, monitored by the detection device 4. These quality parameters are not arbitrarily selected but directly related to sawing quality. The data acquisition module 120 is responsible for communication protocol parsing, data verification, and buffering with the detection device 4 to ensure the continuity and integrity of the quality parameters. In this example, the quality parameters include: Dimensional parameters: The length deviation (ΔL) of workpiece 9 is obtained by detecting the pusher cylinder 401. The length deviation (ΔL) of workpiece 9 cut by a normal saw blade is usually no more than 0.1mm. With wear, the length deviation (ΔL) will systematically increase or exhibit abnormal fluctuations. Cross-sectional parameters: The average burr height (H), cross-sectional roughness rating, or chipped area ratio are calculated by image processing algorithms from the cut end face of workpiece 9 captured by the detection camera 402. In this embodiment, the average burr height (H) is mainly used as the cross-sectional parameter.

[0066] P2: Quality parameter processing and comprehensive deterioration index calculation. Data processing module 121 processes quality parameters according to the following steps: P21: Cleaning of original quality parameters The original quality parameters are validated, outliers caused by transient disturbances (such as a sudden length deviation (ΔL) greater than 5 mm) are removed, and missing data points are marked.

[0067] P22: Quality Parameter Normalization Each quality parameter is linearly mapped to a normalized index of 0-100 within a preset range for fusion calculation.

[0068] Length deviation index I L calculate: If |ΔL|≤0.15mm (within the standard value range), then I L =0 (no degradation); If 0.15mm < |ΔL| ≤ 0.5mm (within the warning threshold range), then I L =(|ΔL|-0.15) / (0.5-0.15)×100; If |ΔL|>0.5mm (above the limit threshold), then I L =100 (severely degraded).

[0069] Burr average height index I H Calculation (same principle, different numerical range): Normalize the measured average burr height (H) according to the following rules: If H ≤ 0.5 mm (lower limit of standard value), then I H =0 (no degradation) If 0.5mm < H ≤ 1.5mm (within the standard value range), then I H =(H-0.5) / (1.5-0.5)×100 (linear mapping to 0-100); If 1.5mm < H ≤ 2.0mm (within the warning threshold range), then I H =100+(H-1.5) / (2.0-1.5)×50; If H > 2.0 mm (above the limit threshold), then I H =100 (severely degraded).

[0070] P23: Calculation of Overall Deterioration Index The normalized indices in P22 are weighted and merged according to preset weights to calculate the Comprehensive Deterioration Index (CDI). CDI=W L ×I L +W H ×I H , For example: If I L =40, I H =60, then CDI = 0.6 × 40 + 0.4 × 60 = 48 P24: Dynamic Threshold Calculation Calculate the dynamic threshold: T = T base ×k m ×k v P25: Output Results The data processing module 121 encapsulates the current workpiece 9's Comprehensive Deterioration Index (CDI), the current dynamic threshold T, and the comparison result into a data packet and transmits it to the trend analysis module 122. These data packets form a continuous data stream according to the processing sequence of workpiece 9. Among them, the comparison result is a structured judgment conclusion, which includes at least the out-of-limit state (true when the Comprehensive Deterioration Index (CDI) > the current dynamic threshold T) and the "out-of-limit magnitude" (CDI minus T, i.e., the Comprehensive Deterioration Index (CDI) minus the current dynamic threshold T).

[0071] Through the above process, the data processing module 121 transforms multi-dimensional and different-dimensional quality parameters into a comprehensive degradation index (CDI) that can intuitively reflect the wear status of the saw blade, and provides accurate input data for subsequent trend analysis and maintenance decisions.

[0072] The trend analysis module 122 receives a continuous data stream from the data processing module 121 (i.e., the Comprehensive Deterioration Index (CDI) of each workpiece 9 and its comparison with the current dynamic threshold T). Its core task is to identify the systematic deterioration trend of the saw blade's cutting performance and filter out random fluctuations. The workflow of the trend analysis module 122 is as follows: A1: Data Buffering and Sequence Construction Trend analysis module 122 maintains a first-in, first-out (FIFO) data buffer, storing the Comprehensive Deterioration Index (CDI) values ​​and corresponding out-of-limit states for a recent period (e.g., the most recent 200 workpieces 9) in chronological order, forming a CDI time sequence {CDI1, CDI2, ..., CDI...}. t} and the sequence of over-limit states, where t is the current workpiece number.

[0073] A2: Key Trend Feature Extraction Online analysis was performed on the above CDI time series to extract the following key trend features: 1. Sliding window mean / median: Calculate the arithmetic mean and median of the Comprehensive Deterioration Index (CDI) of the most recent N (e.g., N=30) workpieces 9 to smooth out transient noise and observe short-term performance levels; 2. Degradation Slope: Perform linear regression on all or part of the CDI time series in the data buffer and calculate its degradation slope ktrend. |ktrend|>0 indicates that the comprehensive degradation index (CDI) is on an upward trend (performance is degrading), and its absolute value reflects the rate of degradation. 3. Exponential Exceedance Ratio: Based on the continuous exceedance status records obtained from the data packet, the proportion of workpieces exhibiting exponential exceedances within the sliding window is recorded as the exceedance ratio P. alert Among them, index overrun refers to the event where the Comprehensive Deterioration Index (CDI) exceeds the current dynamic threshold T; 4. Fluctuation Standard Deviation: To identify abnormal fluctuations, the trend analysis module maintains a deterioration slope sequence {ktrend1,ktrend2,...,ktrend} containing the most recent m analysis periods (e.g., m=10). m}, and calculate the standard deviation σ of the fluctuation of the deterioration slope sequence, as follows: Calculate the series mean: Where i is the period number, ktrend i Let be the degradation slope of the i-th cycle, and m be the total number of analysis cycles selected. Standard deviation of fluctuation: The standard deviation of the fluctuation, σ, is used to quantify the dispersion of the degradation slope, ktrend. A larger σ value indicates more severe fluctuations in the degradation rate, suggesting abnormal or unstable saw blade condition. 5. Proportional fluctuation value: used to identify out-of-limit proportions P alertThe abnormal fluctuations are recorded by the trend analysis module 122, which records the out-of-limit ratio sequence for the most recent k analysis periods (k is an integer greater than 1, such as k=3). This out-of-limit ratio sequence must contain k consecutive values, including the current latest period. Let the current period be the t-th analysis period, then the out-of-limit ratio sequence is {P}. alert (t-k+1)),P alert (t-k+2)),...,P alert Δ(t) represents the out-of-limit ratio over k consecutive periods, including the current period. The absolute value of the difference between all adjacent values ​​in the out-of-limit ratio sequence is calculated, and the maximum value is taken as the ratio fluctuation value Δ. max .

[0074] Proportional fluctuation value Δ max Used to quantify the excess ratio P alert The short-term fluctuation range. Δ max The larger the value, the more drastic the fluctuation of the over-limit ratio between adjacent cycles, indicating a sudden change in the saw blade's condition.

[0075] A3: Working Condition Correlation and Segmentation Analysis To more accurately analyze the time-series variation trend of the Composite Deterioration Index (CDI), the trend analysis module 122 correlates the data stream with the processing log of the sawing machine 1. When the sawing machine 1 changes the processing material or adjusts the feed speed, the trend analysis module 122 automatically segments the data. For example, analyzing the CDI trend of "processing stainless steel batches" and "processing aluminum batches" separately can effectively avoid misjudgments of trends caused by changes in operating conditions, thus improving the accuracy of condition assessment, since the wear mechanisms and wear rates of different materials are significantly different.

[0076] A4: Key Thresholds and Rules for Determining Trend Status A41, Key Judgment Threshold To comprehensively evaluate the performance status of the saw blade, the maintenance system 12 presets the following key judgment thresholds to quantify the rate of degradation, degree of exceeding limits, and fluctuation characteristics: The first slope threshold K1 is used to distinguish between "stable" and "beginning to deteriorate". When the deterioration slope |ktrend| ≤ K1, it is considered that the saw blade performance has no obvious trend change. In this embodiment, K1 = 0.05. The second slope threshold K2 (K2 > K1): is used to distinguish between "slow degradation" and "accelerated degradation". When the degradation slope ktrend > K2, the degradation rate is considered to have entered an accelerated phase that requires high attention. In this example, K2 = 0.2. Excess percentage threshold P1: Used to define the acceptable excess percentage of workpiece 9. In this example, P1 = 10%. Fluctuation standard deviation threshold σ max: Used to determine whether the dispersion of the deterioration slope ktrend sequence constitutes abnormal fluctuation. In this example, σ max =0.15; Proportional fluctuation threshold δP: used to determine the proportion P exceeding the limit. alert Does the fluctuation range between periods constitute abnormal volatility? In this example, δP = 25%; Growth threshold ΔP: Used to determine whether the cumulative growth rate of the excess proportion exceeds the limit within a continuous period. When P exceeds the limit within k consecutive periods... alert When the cumulative increase exceeds ΔP, it is determined that the sawing performance of the saw blade is deteriorating at an accelerated rate. In this example, ΔP = 20%.

[0077] All thresholds can be configured according to specific process requirements.

[0078] A42. Trend Status Determination Rules: Determining the Current Trend Status Based on the extracted key trend features, the current trend status is determined according to the following criteria: Stable: Deterioration slope |ktrend| ≤ K1 (K1 = 0.05), and the excess proportion P alert ≤P1 (P1=10%) Slow degradation: K1 < ktrend ≤ K2 (K2 = 0.2), and the over-limit ratio P alert It shows a continuous upward trend (e.g., P within 3 consecutive cycles). alert The value is monotonically increasing, allowing for periods where the increase in adjacent periods is less than 0.5% (the value remains flat). Accelerated degradation: Degradation is defined as occurring when any of the following conditions are met: The degradation slope ktrend > K2; Excess ratio P alert The growth amount within a continuous analysis period exceeds the preset growth threshold ΔP (e.g., the cumulative growth exceeds 20% for 3 consecutive periods). Excess ratio P alert A persistently high level is defined as, for example, when M out of N consecutive workpieces 9 have a CDI exceeding the dynamic threshold T. In this embodiment, N=10 and M=7, meaning that if more than 7 out of 10 consecutive workpieces exceed the limit, it is considered a persistently high level. Severe fluctuations: When the standard deviation of the fluctuation of the deteriorated slope sequence σ > σ max And the proportional fluctuation value Δ max When the value is greater than δP, it is considered a violent fluctuation.

[0079] A5: Output trend analysis results Trend Analysis Module 122 will display the core conclusions for the current analysis period, including the latest arithmetic mean of the Composite Deterioration Index (CDI) within the sliding window, the current deterioration slope ktrend, and the over-limit ratio P. alert The trend status is encapsulated into a structured "trend analysis result" and sent to the maintenance and prediction module 123.

[0080] The workflow for maintaining prediction module 123 is as follows: The maintenance prediction module 123 is the decision center. It integrates real-time trend analysis results with maintenance decision-making logic and historical databases to output specific maintenance instructions. The maintenance decision-making process includes the following steps: B1: Multi-source information fusion and maintenance decision triggering The maintenance prediction module 123 receives the "trend status" and "trend analysis results" output by the trend analysis module 122, and integrates the following information to make a decision: Life prediction results: The preset life prediction model is called, and the real-time CDI time series of the current saw blade is matched with the full life cycle deterioration curves with similar working condition labels stored in the historical database to output the percentage of remaining life or the number of remaining workpieces. The pre-defined maintenance decision logic involves taking different maintenance actions based on different combinations of "trend status" and "lifespan prediction results." For example, maintenance is triggered when the trend status is determined to be "accelerated degradation" and the predicted remaining lifespan is less than one production batch.

[0081] B2: Generate graded maintenance signals The maintenance prediction module 123 generates graded maintenance signals according to the trend status in the received "trend analysis results" and integrates the life prediction results information in B1, following the rules below: Observational signal: When the trend status is "stable" or "slowly deteriorating," it is determined to be an observation period. The maintenance system 12 can display a normal status or prompt "Performance is slowly declining, it is recommended to pay attention" on the human-machine interface 6 without interrupting production; Warning-level signal: When the trend status is "accelerated deterioration", it is determined that planned maintenance is required. The maintenance system 12 generates a "maintenance reminder signal", which may include: "It is recommended to perform saw blade re-sharpening after processing XX workpieces 9 in the future", and can adjust the production rhythm in advance based on the prediction results (such as reducing the feeding speed of the buffer conveyor line 3); Maintenance-level signal: When the trend status is "violent fluctuation", it is determined that there is a high risk of sudden damage (such as tooth breakage) and immediate intervention is required. The maintenance system 12 generates a "fast maintenance signal" with the highest priority, triggers an audible and visual alarm, and suggests or directly performs a shutdown inspection.

[0082] B3: Drive electronic control system with 7 linkages (closed-loop control) The maintenance signal is not only displayed, but also directly drives the action of saw 1, realizing a closed loop of predictive maintenance: Adjusting production rhythm and orderly shutdown: After issuing a "maintenance-level reminder signal," the maintenance prediction module 123 determines that the saw blade has entered an accelerated deterioration stage. Although it is not completely ineffective, continuing full-speed production will lead to a rapid increase in the defect rate. At this time, the maintenance prediction module 123 sends an instruction to the electrical control system 7 to gradually reduce the feeding speed of the buffer conveyor line 3. The pace of downstream inspection and sorting processes slows down accordingly, and the workpieces 9 on the buffer conveyor line 3 gradually accumulate, sending a "demand saturation" signal upstream. Ultimately, after completing the current cut, the upstream saw 1 will naturally enter a waiting state because there is no conveying position on the buffer conveyor line 3.

[0083] Generate and push work orders: Automatically convert structured maintenance reminder signals into maintenance work orders, push them to the workshop's maintenance management system (MES / CMMS), and notify relevant personnel.

[0084] Maintenance system 12 also includes a self-learning module 124, which has data storage and self-learning functions. Each complete data chain from alert to maintenance is stored in a structured format in a historical database. These complete data chains mainly include: Quality parameters and processing data: namely, the quality parameters (such as length deviation ΔL, average burr height H) acquired by the data acquisition module 120, and the comprehensive degradation index (CDI), current dynamic threshold T, and over-limit range (CDI-T) calculated and output by the data processing module 121.

[0085] Key trend characteristic data: This refers to the trend analysis results output by the trend analysis module 122, which mainly include: Deterioration slope ktrend; The over-limit ratio P within the sliding window alert ; The final trend status is determined (e.g., "stable" or "accelerated deterioration").

[0086] Decision and execution data: This refers to the decision inputs, decision outputs, and execution feedback of the prediction module 123, including: Decision input: The specific rule that triggers this maintenance (e.g., "due to P") alert (Triggered for 3 consecutive cycles > 60%) Decision output: The type and content of the generated maintenance signal (e.g., "Maintenance reminder signal - recommended grinding"). Execution feedback: Record the actual handling result of the saw blade after this maintenance (such as "replace with a new saw blade" or "reinstall after resharpening") and the subsequent initial comprehensive degradation index (CDI) to form a "prediction-result" closed loop.

[0087] These complete data chains are also used in the following self-learning optimization process: Optimize the dynamic threshold model: By analyzing multiple historical CDI time series and their operating conditions in the historical database, automatically correct the parameters in the current dynamic threshold T calculation, such as the base threshold T. base The hardness influence coefficient α and the reference feed rate v0) make the current dynamic threshold T setting more accurate; Optimize lifetime prediction model: Utilize data from accumulated complete lifecycle degradation curves to continuously iterate and update the lifetime prediction model, thereby improving the accuracy of remaining lifetime prediction; Optimize core parameters and decision logic: Based on the analysis of the complete data chain stored in the historical database, adaptively adjust the weight coefficients of data fusion (length deviation weight W). L Average height weight of burrs W H Thresholds and conditions in trend state determination (such as first slope threshold K1, second slope threshold K2, over-limit ratio threshold P1, growth threshold (ΔP), fluctuation threshold (fluctuation standard deviation threshold σ)). max The system incorporates parameters such as the proportional fluctuation threshold δP, specific condition values ​​(N,M) like "M out of N consecutive workpieces exceed limits", dynamic threshold T calculation parameters, and maintenance decisions, making the maintenance system's decisions more aligned with actual production quality and efficiency requirements.

[0088] Through the above process, the maintenance system 12 can continuously accumulate knowledge during operation and achieve online adaptive optimization of dynamic threshold model parameters, life prediction model parameters and maintenance decision logic parameters, that is, the self-learning capability of the maintenance system 12.

[0089] Through the collaborative work of the above five modules (data acquisition module 120, data processing module 121, trend analysis module 122, maintenance prediction module 123 and self-learning module 124), the maintenance system 12 realizes a complete closed loop from raw data to intelligent decision-making to production linkage and self-optimization, reflecting the intelligent characteristics of the present invention from "perception" to "decision" to "execution" and "learning".

[0090] Example 8, referring to Figure 7 A conveying method for use in the above-mentioned intelligent buffering, detection, sorting and maintenance system at the output end of a sawing machine includes the following steps: S1: Workpiece 9 and scrap are output from sawing machine 1. The first sensor identifies the workpiece and scrap. S2: If it is workpiece 9, the material distribution baffle 203 remains in its original position to block workpiece 9, and the pushing module 201 pushes workpiece 9 into the buffer conveyor line 3; S3: If it is waste material, the material distribution baffle 203 slides upward, and the waste material continues to flow along the chain conveyor line from below the material distribution baffle 203 until it flows out from the waste material conveying port 204 into the waste material collection device 8. S4: Workpiece 9 enters the buffer conveyor line 3 for buffering, and then flows into the detection device 4 for detection; S5: The detection pusher cylinder 401 pushes the workpiece into the detection device 4, the length measuring baffle 409 extends, and at the same time, the detection camera 402 takes pictures of the cross-section of the workpiece 9 to detect its cross-section quality. When the detection pusher plate 403 pushes the workpiece 9 to contact the length measuring baffle 409, the pushing stops. Based on the stroke of the detection pusher cylinder 401, it is determined whether the length of the workpiece 9 is qualified. S6: Detect the retraction of the pusher cylinder 401 and the length measuring baffle 409, and detect the ejection of the lifting cylinder 404, so that the workpiece 9 is removed from the support of the roller conveyor mechanism. The weighing sensor 405 measures the weight of the workpiece 9 and determines whether the weight is qualified. S7: After inspection, workpiece 9 is transferred to the waste rejection conveyor line 5; S8: If qualified, workpiece 9 is pushed out from the qualified product exit 507. S9: If it is not qualified, the rejection baffle 501 descends to intercept the unqualified workpiece 9, and the rejection push plate 503 pushes the unqualified workpiece 9 from the rejection outlet 504 into the waste collection device 8. S10: During the inspection of workpiece 9, the size parameters and / or cross-sectional parameters of workpiece 9 monitored by the inspection device 4 are transmitted to the maintenance system 12 to determine whether the saw blade needs maintenance and trigger a maintenance signal.

[0091] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A smart buffering, detection, sorting and maintenance system for the discharge end of a sawing machine, comprising a sawing machine (1), wherein the discharge end of the sawing machine (1) is connected to a discharge conveying device, characterized in that, The discharge conveying device includes: The discharge conveyor line (2) is set at the discharge end of the saw (1) to receive and convey the cut workpiece (9) and waste material; A buffer conveyor line (3) is arranged adjacent to the discharge conveyor line (2) for receiving and buffering workpieces (9) from the discharge conveyor line (2). The detection device (4) is set at the end of the buffer conveyor line (3) to detect the workpiece (9) from the buffer conveyor line (3) and output quality parameters; The waste conveyor line (5) is connected to the end of the detection device (4) and is used to convey the detected workpiece (9). Waste collection device (8): used to collect waste and defective workpieces (9); The electrical control system (7) is communicatively connected to the discharge conveyor line (2), the buffer conveyor line (3), the detection device (4), and the waste rejection conveyor line (5), respectively; Maintenance system (12), which is integrated into the electrical control system (7), is used to predict the maintenance needs of the saw blade of the sawing machine (1); The electronic control system (7) is configured as follows: Control the diversion and transfer of workpiece (9) and waste material on the discharge conveyor line (2); Control the rhythm of the buffer conveyor line (3) conveying the workpiece (9) to the detection device (4); The waste removal conveyor line (5) is controlled to perform sorting based on the quality parameters of the detection device (4).

2. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 1, characterized in that, The discharge conveyor line (2) includes a first chain conveyor line, a pushing module (201) and a distributing module. The pushing module (201) is located on one side of the discharge conveyor line (2), and the output end of the pushing module (201) corresponds to the buffer conveyor line (3). The material distribution module includes a baffle lifting cylinder (202) and a material distribution baffle (203). The baffle lifting cylinder (202) is fixedly connected to the downstream side of the discharge conveyor line (2). The output end of the baffle lifting cylinder (202) is connected to one end of the material distribution baffle (203). A baffle mounting frame is provided on the first chain conveyor line. The material distribution baffle (203) is slidably connected to the baffle mounting frame. A waste material conveying port (204) is also connected to the end of the discharge conveyor line (2).

3. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 2, characterized in that, The buffer conveyor line (3) is a chain plate conveyor line, and a buffer limiting baffle (301) is provided at the lower end of the buffer conveyor line (3). The conveying direction of the buffer conveyor line (3) is perpendicular to the discharge conveyor line (2); The discharge conveyor line (2), buffer conveyor line (3) and detection device (4) are fixed on the upper plane of the first frame (10), and the waste rejection conveyor line (5) and electrical control system (7) are set on the second frame (11).

4. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 3, characterized in that, The detection device (4) includes a pusher cylinder mounting bracket (410), which is fixed to one end of the first frame (10). The top of the pusher cylinder mounting bracket (410) is higher than the first frame (10). A detection pusher cylinder (401) is installed on the pusher cylinder mounting bracket (410). A detection pusher plate (403) is installed at the output end of the detection pusher cylinder (401). A detection camera (402) is provided on the detection pusher plate (403) near the end of the discharge conveyor line (2). The running direction of the detection pusher cylinder (401) is perpendicular to the conveying direction of the buffer conveyor line (3).

5. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 4, characterized in that, The detection device (4) also includes a weighing device, which is located below the detection pusher cylinder (401) and includes a weighing support platform. A weighing lifting cylinder (404) is provided above the weighing support platform. A weighing sensor (405) is connected to the output end of the weighing lifting cylinder (404). A weighing support frame (406) is provided on the top of the weighing sensor (405). Multiple support claws are provided on the top of the weighing support frame (406).

6. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 5, characterized in that, The weighing device also includes a roller conveying mechanism, which includes a detection conveying motor (411), a drive roller (407), and multiple driven rollers. The drive roller (407) and multiple driven rollers are arranged at intervals along the conveying direction. The two ends of the conveying roller (407) are rotatably supported on the guard plate by bearings. The guard plate is fixedly installed on the upper surface of the first frame (10). The output end gear of the detection conveying motor (411) is connected to a first sprocket, the first sprocket meshes with a drive gear, the drive gear is sleeved on one end of the drive roller (407), the drive gear meshes with a second sprocket, and the second sprocket meshes with one end of a plurality of driven rollers; Multiple of the aforementioned support claws shuttle between the roller conveyor mechanism; The end of the roller conveyor mechanism is also provided with a length measuring baffle (408), and the bottom end of the length measuring baffle (408) is connected to the output end of the length measuring baffle lifting cylinder (409).

7. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 3, characterized in that, The waste removal conveyor line (5) includes a third chain conveyor line and a waste removal baffle (501). The waste removal baffle (501) spans the third chain conveyor line. The waste removal baffle (501) is slidably connected to the waste removal baffle mounting frame. One end of the waste removal baffle (501) is connected to the output end of the waste removal lifting cylinder (502). The third chain conveyor line is provided with a waste removal push plate (503) and a waste removal outlet (504) on both sides, and the waste removal push plate (503) is located in front of the waste removal baffle (501). Behind the rejection baffle (501), a qualified product baffle (505) is also provided. The qualified product baffle (505) spans across the third chain conveyor line. A corresponding qualified product push plate (506) and a qualified product outlet (507) are also provided between the rejection baffle (501) and the qualified product baffle (505), and are respectively provided on both sides of the rejection conveyor line (5). The rejection pusher (503) pushes out the unqualified workpiece (9) from the rejection outlet (504), and the qualified product pusher (506) pushes out the qualified workpiece (9) from the qualified product outlet (507). The waste rejection outlet (504) and the qualified product outlet (507) are cylindrical guide rod array type outlets.

8. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 1, characterized in that, The discharge conveyor line (2) and the rejection conveyor line (5) respectively guide the waste and the unqualified workpieces (9) to the waste collection device (8).

9. The intelligent buffering, detection, sorting and maintenance system for the output end of a sawing machine according to claim 1, characterized in that, The maintenance system is configured as follows: Acquire at least two independent quality parameters related to saw blade wear, as monitored by the detection device (4), the quality parameters including workpiece dimensional parameters and / or cross-sectional parameters; The quality parameters are normalized and weighted according to predetermined rules to calculate the comprehensive deterioration index. The comprehensive deterioration index is compared with a dynamic threshold, which is adaptively adjusted according to the type of material processed by the saw (1) and / or the feed rate; Maintenance decisions are made based on preset maintenance decision logic. When the comprehensive deterioration index continues to exceed the dynamic threshold, it is determined that the saw blade needs maintenance and a maintenance signal is triggered. Record a complete data chain that includes quality parameters, overall degradation index, trend analysis results, and maintenance decisions; The complete data chain is analyzed to adaptively optimize the weights of each quality parameter, the calculation parameters of the dynamic threshold, or the maintenance decision logic.

10. A conveying method, employing the intelligent buffering, detection, sorting and maintenance system at the output end of a sawing machine as described in claim 6, comprising the following steps: S1: The workpiece (9) and scrap are output from the saw (1), and the workpiece (9) and scrap are identified. S2: If it is a workpiece (9), the material distribution baffle (203) remains in place, blocking the workpiece (9), and the pusher module (201) pushes the workpiece (9) into the buffer conveyor line (3). S3: If it is waste material, the material distribution baffle (203) slides upward, and the waste material continues to flow along the discharge conveyor line (2) from below the material distribution baffle (203) until it flows out from the waste material conveyor (204) into the waste material collection device (8); S4: The workpiece (9) enters the buffer conveyor line (3) for buffering, and then flows into the detection device (4) for detection; S5: The detection pusher cylinder (401) pushes the workpiece into the detection device (4), the length measuring baffle (408) extends, and at the same time, the detection camera (402) takes pictures of the cross-section of the workpiece (9) to detect its cross-sectional quality. When the detection pusher plate (403) pushes the workpiece (9) to contact the length measuring baffle (408), the pushing stops. Based on the stroke of the detection pusher cylinder (401), the length of the workpiece (9) is detected to be qualified. S6: Detect the retraction of the pusher cylinder (401) and the length measuring baffle (409), and detect the ejection of the lifting cylinder (404) to make the workpiece (9) detach from the support of the roller conveyor mechanism. The weighing sensor (405) measures the weight of the workpiece (9) and determines whether the weight is qualified. S7: After inspection, the workpiece (9) is transferred to the scrap conveyor line (5); S8: If qualified, the workpiece (9) is pushed out from the qualified product exit (507). S9: If it is not qualified, the rejection baffle (501) descends to intercept the unqualified workpiece (9), and the rejection pusher (503) pushes the unqualified workpiece (9) from the rejection outlet (504) into the waste collection device (8); S10: During the inspection of the workpiece (9), the maintenance system (12) predicts the maintenance needs of the saw blade of the sawing machine (1).

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