A full-automatic anchor rod blanking production device of a beveling band saw machine

Abstract

The application relates to the technical field of sawing machines, in particular to a full-automatic anchor rod blanking production device of a slant-cut band sawing machine, which comprises a support, an electrical box, a mounting frame, a sawing mechanism, an anchor rod feeding mechanism, a clamping mechanism, a discharging platform and a control console, the mounting frame is provided with a slant-cut driving assembly capable of adjusting a sawing angle, the sawing mechanism comprises a sawing belt and a matched sawing belt maintaining and cleaning assembly, the anchor rod feeding mechanism can automatically feed different diameter anchor rods, the clamping mechanism is provided with a floating clamping and temperature and displacement monitoring assembly, and self-adaptive centering clamping and overheating protection of the anchor rod are realized. The full-automatic anchor rod blanking production device of the slant-cut band sawing machine can realize continuous and stable adjustment of a sawing angle through the slant-cut driving assembly and a self-locking transmission structure, the machining process is not prone to deviation caused by cutting force, the angle consistency and the cut precision of straight cutting and slant cutting of the anchor rod are improved, and the sawing belt can be stably supported and cleaned in real time through cooperation of the sawing belt maintaining and cleaning assembly.

Description

Technical Field

[0001] This invention relates to the field of band sawing technology, specifically to a fully automatic anchor bolt cutting production device with a bevel-cutting band saw. Background Technology

[0002] As a core load-bearing component in geotechnical engineering support systems such as mines, tunnels, and slopes, the accuracy of anchor bolt cutting, the quality of the cut, and the processing efficiency directly determine the reliability of the support structure and the construction cost. Currently, the industry commonly uses band saws to cut anchor bolts to a fixed length and process them at angles. However, traditional band saws generally suffer from insufficient automation and coordination in large-scale anchor bolt cutting operations. They lack integrated functions such as beveling adjustment, adaptive clamping, online monitoring, and saw band protection. This results in common technical bottlenecks such as unstable processing quality, low production efficiency, high reliance on manual labor, and high equipment wear, making it difficult to meet the industrial production requirements of high-precision, high-efficiency, and high-consistency anchor bolts.

[0003] While there are some improvement solutions in the existing technology, none of them have been able to systematically solve the above-mentioned core problems.

[0004] Comparative document 1: CN218517825U discloses an anchor bolt cutting and processing equipment, which adopts a fixed clamping and conventional conveying structure and can realize basic cutting operations, but it does not have a bevel cutting angle adjustment mechanism, which cannot meet the requirements for bevel cutting of anchor bolts; the clamping mechanism is a rigid structure, which has poor adaptability to bent anchor bolts and is prone to clamping eccentricity and cutting tilt; at the same time, it lacks online saw blade cleaning and temperature and displacement monitoring functions, which can easily lead to uneven saw blade wear and workpiece overheating and deformation during long-term operation, and the degree of automation and processing stability are limited.

[0005] Comparative document 2: CN219464940U discloses a rotary band saw that achieves multi-angle cutting by rotating the workpiece, which improves the flexibility of beveling to a certain extent. However, this structure requires the workpiece to be rotated as a whole, which has poor adaptability to long anchor rods. The rotation process is prone to eccentricity and vibration, affecting the dimensional accuracy. The clamping method is still conventional rigid clamping, without adaptive floating clamping and intelligent monitoring unit, which cannot avoid defects such as uneven clamping pressure and friction heating. In addition, the saw band holding and cleaning mechanism is not integrated, and the saw band service life and cut quality are difficult to guarantee continuously.

[0006] Reference document 3: CN213531045U discloses a sawing machine for producing mining anchor bolts. It achieves clamping and length setting through a manual adjustment mechanism. The structure is simple and the cost is low, but it relies entirely on manual intervention and has a very low level of automation. The bevel cutting angle needs to be repeatedly adjusted and calibrated manually, resulting in poor adjustment accuracy and low consistency. The clamping mechanism lacks self-adaptive and monitoring protection functions, which can easily cause surface damage and deformation of the anchor bolts, resulting in many burrs on the cut. At the same time, it lacks stable support and cleaning maintenance for the saw blade, resulting in insufficient stability in continuous processing and making it difficult to adapt to mass production scenarios.

[0007] In summary, existing anchor bolt cutting band saws generally fail to achieve integrated functionality encompassing precise adjustment of the bevel angle, adaptive floating clamping, intelligent temperature and displacement monitoring, stable saw blade maintenance and online cleaning, and fully automatic feeding and closed-loop control. This results in problems such as insufficient positioning accuracy, poor angle consistency, easy workpiece damage, rapid saw blade wear, excessive manual intervention, and difficulty in simultaneously improving production efficiency and product qualification rate during the anchor bolt cutting process. These issues severely restrict the intelligent and large-scale development of anchor bolt processing. Therefore, developing a dedicated anchor bolt cutting production device capable of bevel cutting, fully automatic operation, adaptive clamping, intelligent monitoring, and saw blade protection has become a critical technical problem urgently needing to be solved in the industry. Summary of the Invention

[0008] The purpose of this invention is to provide a fully automatic anchor bolt cutting production device with a bevel cutting band saw, so as to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a fully automatic anchor bolt feeding and production device with a beveling band saw, comprising a support frame, an electrical box, a mounting frame, a sawing mechanism, an anchor bolt feeding mechanism, a clamping mechanism, a discharge platform, and a control console. The mounting frame is equipped with a beveling drive assembly with an adjustable sawing angle. The sawing mechanism includes a saw band and matching saw band holding and cleaning components. The anchor bolt feeding mechanism is adaptable to automatically feeding anchor bolts of different diameters. The clamping mechanism is equipped with floating clamping and temperature and displacement monitoring components to achieve adaptive centering clamping and overheat protection for the anchor bolts. The electrical box, sawing mechanism, feeding mechanism, and clamping mechanism are all electrically connected to the control console to achieve fully automatic feeding and beveling control.

[0010] Preferably, the oblique cutting drive assembly includes a second motor, a transmission box, a first turntable box, a worm gear, a worm wheel, a rotating shaft, a first turntable, a second turntable box, a lead screw mechanism, and a handwheel; the second motor drives the worm gear and worm wheel through the transmission box, causing the first turntable to rotate; the distance of the second turntable is adjusted by the lead screw mechanism and the handwheel, and the tension of the saw band by the first turntable and the second turntable achieves the adjustment of the sawing and oblique cutting angles.

[0011] Preferably, the saw band holding and cleaning assembly includes a retainer, a guide rail, a connecting frame, an adjusting block, a clamping block, a cleaning block, and an adjusting bolt; the retainer slides along the guide rail, the adjusting block drives the clamping block to clamp the cleaning block through the adjusting bolt, and the cleaning block contacts the saw band to achieve online cleaning and replacement.

[0012] Preferably, the anchor bolt feeding mechanism includes a hydraulic cylinder, a first mounting plate, a second mounting plate, a first rotating wheel, a second rotating wheel, and an adjuster; the adjuster adjusts the position of the second mounting plate and changes the distance between the first rotating wheel and the second rotating wheel to adapt to anchor bolts of different diameters, and the hydraulic cylinder drives the feeding action.

[0013] Preferably, the clamping mechanism includes a clamping frame, a clamping ring, a through groove, a telescopic rod, a vent pipe, an air valve, a pre-tightening ring, a locking plate, a floating clamping plate, a displacement sensor, and a temperature sensor; the vent pipe vents air to drive the telescopic rod to center and clamp the anchor rod with the pre-tightening ring; the floating clamping plate is provided with a polytetrafluoroethylene wear-resistant layer, the displacement sensor monitors the clamping displacement, the temperature sensor monitors the contact temperature, and when the temperature exceeds the limit, the clamping force is reduced and air cooling is activated.

[0014] Preferably, the pre-tightening ring is provided with an annular groove, an axial pre-tightening cylinder, a pre-tightening shaft, and a connecting rod; the axial pre-tightening cylinder drives the pre-tightening shaft and the connecting rod, thereby driving the locking plate and the floating clamp to achieve adaptive floating clamping and automatic reset when the displacement exceeds the limit.

[0015] Preferably, it also includes an auxiliary clamping mechanism consisting of a motor, a reducer, a lead screw frame, a lead screw, a lead screw nut, a movable clamping plate, and a fixed clamping plate; the motor drives the lead screw through the reducer, which in turn moves the movable clamping plate, and works with the fixed clamping plate to achieve auxiliary clamping and positioning of the anchor bolt.

[0016] Preferably, the worm gear, worm wheel, and rotating shaft are integrated into a turntable box one, and the relative positions of turntable box one and turntable box two are adjustable, so as to realize continuous adjustment of saw band tension and beveling angle.

[0017] Preferably, the cleaning block has a replaceable structure, the adjusting bolts enable stepless adjustment of the clamping force, and the retainer can slide along the guide rail to switch between shutdown maintenance and online cleaning.

[0018] Preferably, the control console integrates a PLC control unit, which receives signals from displacement and temperature sensors, and automatically controls the feed speed, clamping force, sawing speed, and bevel angle to achieve fully automatic length setting, straight cutting, and bevel cutting of anchor rods.

[0019] Compared with the prior art, the beneficial effects of the present invention are: 1. This fully automatic anchor bolt blanking production device, featuring a beveling band saw, utilizes a beveling drive assembly and a worm gear self-locking transmission structure to achieve continuous and stable adjustment of the sawing angle. The angle locking is reliable, and the processing is less susceptible to deviation due to cutting forces. This improves the consistency of angles and cut accuracy in both straight and beveling anchor bolt cutting. Combined with a saw band holding and cleaning assembly, it provides stable support and real-time cleaning of the saw band, reducing saw band vibration, sway, and wear from impurities, extending saw band lifespan, and lowering consumable costs. Simultaneously, it ensures a smooth, burr-free cut, improving the quality of the anchor bolt blanking end face, providing a good foundation for subsequent processing steps, and enhancing overall product qualification rate and operational safety.

[0020] 2. This fully automatic anchor bolt blanking production device, which can be used for oblique cutting band sawing, adopts a clamping structure that combines pneumatic centering with adaptive floating clamping. It can quickly achieve automatic centering of anchor bolts, avoiding eccentricity and tilting. At the same time, the floating clamping plate can adaptively fit the shape of the anchor bolt, so that the clamping pressure is evenly distributed, reducing workpiece deformation, indentation and surface damage caused by local stress concentration. With the help of displacement and temperature monitoring unit, it can identify the clamping status and friction temperature rise in real time, realize abnormal automatic reset and overheat protection, avoid workpiece thermal deformation and equipment overload, improve clamping stability and processing safety, adapt to the efficient and stable processing of anchor bolts with different diameters and straightness, and expand the application range of the equipment.

[0021] 3. This fully automatic anchor bolt cutting production device, which can be used for oblique cutting band sawing, achieves fully automated operation of the entire process of feeding, centering, clamping, feeding, sawing, and unloading through the closed-loop coordinated control of the anchor bolt feeding mechanism, clamping mechanism, sawing mechanism, and control console. It eliminates the need for frequent manual intervention, reduces the labor intensity of operators, minimizes human error, and improves processing continuity and production efficiency. The feeding mechanism can flexibly adapt to anchor bolts of different diameters, is easy to adjust, and has reliable clamping. It forms a dual positioning with the auxiliary clamping mechanism, further improving the processing stability of long anchor bolts and large-diameter anchor bolts, ensuring dimensional accuracy, meeting the needs of large-scale and continuous production, and improving the overall capacity and operating economy of the production line. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the rear structure of the mounting bracket of the present invention; Figure 3 This is a schematic diagram of the cage structure of the present invention; Figure 4 This is a schematic diagram of the lead screw frame structure of the present invention; Figure 5 This is a schematic diagram of the saw blade structure of the present invention; Figure 6 for Figure 5 Enlarged schematic diagram of the structure at point A in the middle; Figure 7 This is a schematic diagram of the anchor bolt feeding mechanism of the present invention; Figure 8 This is a schematic diagram of the overall structure of the clamping mechanism of the present invention; Figure 9This is a schematic diagram of the floating clamping plate structure of the present invention.

[0024] In the diagram: 1. Bracket; 2. Electrical box; 3. Mounting bracket; 301. Motor II; 302. Transmission box; 303. Turntable box I; 304. Worm gear; 305. Worm wheel; 306. Shaft; 307. Turntable I; 308. Saw blade; 309. Turntable box II; 310. Screw mechanism; 311. Handwheel; 312. Turntable; 4. Cage; 401. Guide rail; 402. Connecting bracket; 404. Adjusting block; 405. Groove; 406. Clamping block; 407. Cleaning block; 408. Adjusting bolt; 5. Anchor bolt feed mechanism; 501. Hydraulic cylinder; 502. Mounting plate I; 503. Mounting plate II; 504. Rotary wheel I; 505. Rotary wheel II; 506. Adjuster; 6. 7. Discharge platform; 8. Control console; 9. Clamping frame; 10. Clamping ring; 11. Through groove; 12. Telescopic rod; 13. Vent pipe; 14. Air valve; 15. Pre-tightening ring; 16. Circular groove; 17. Axial pre-tightening cylinder; 18. Pre-tightening shaft; 19. Connecting rod; 10. Locking plate; 11. Hinge joint; 10. Hinge shaft; 11. Floating clamping plate; 12. Displacement sensor; 13. Mounting groove; 14. Temperature sensor; 15. PTFE wear-resistant layer; 16. Motor 1; 17. Reducer; 18. Screw frame; 19. Screw; 10. Screw nut; 11. Movable clamping plate; 12. Fixed clamping plate. Detailed Implementation

[0025] 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.

[0026] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] Please see Figures 1-9The present invention provides a technical solution: a fully automatic anchor bolt cutting production device with a band saw for oblique cutting, including a bracket 1, an electrical box 2, a mounting frame 3, a sawing mechanism, an anchor bolt feeding mechanism 5, a clamping mechanism, a discharge platform 6, and a control console 7.

[0028] The support frame 1 is made of welded steel profiles with rust-proof and anti-slip treatment. Adjustable feet and shock-absorbing pads are installed at the bottom to ensure the equipment remains stable under continuous heavy loads, preventing shaking, displacement, or resonance, and guaranteeing sawing accuracy. The internal space of the support frame 1 is reserved for the arrangement of hydraulic pipelines, pneumatic pipelines, electrical cables, cooling pipelines, and a recovery tank, achieving pipeline integration and tidiness, avoiding interference, tangling, and wear.

[0029] The electrical box 2 and mounting bracket 3 are fixedly installed on the top of bracket 1, and the two are connected by bolts. Positioning pin holes are machined on the positioning surface to ensure assembly accuracy and repeatability. Electrical box 2 is a closed, dustproof, waterproof, and oil-proof structure. Internally, it houses a PLC controller, switching power supply, contactors, relays, thermal relays, circuit breakers, servo drivers, pneumatic solenoid valve assemblies, hydraulic valve assemblies, temperature control modules, displacement acquisition modules, alarm modules, etc. All electrical components meet industrial-grade standards and are suitable for dusty, humid, and vibrating workshop environments. The panel of electrical box 2 is equipped with an emergency stop button, power switch, reset button, mode selection switch, and fault indicator lights for easy on-site operation and emergency handling.

[0030] Mounting frame 3 is a one-piece cast or thick plate welded structure, with high rigidity and minimal deformation, serving as the mounting carrier for the sawing mechanism, retainer mechanism, and clamping mechanism. The bottom of mounting frame 3 is fixedly connected to the discharge platform 6, which uses an inclined slide rail with wear-resistant PVC strips on the surface, allowing the cut anchor rods to slide out smoothly under their own weight, avoiding bumps and scratches on the end faces. The end of the discharge platform 6 is equipped with a buffer stop and a material collection point, allowing direct connection to a transfer cart or conveyor belt for continuous production.

[0031] The control console 7 is fixedly mounted on the top of the mounting bracket 3. Control console 7 features a combination of a touchscreen and physical buttons. The screen displays real-time feed speed, saw blade speed, clamping pressure, beveling angle, anchor bolt length, processed quantity, operating status, temperature data, displacement data, and fault codes. The physical buttons include start, pause, jog feed, jog retraction, angle adjustment, clamping / releasing, and manual / automatic switching, meeting the needs of debugging, manual operation, and fully automatic operation. Control console 7 has an internal data storage unit that can record processing parameters, fault records, and production statistics, supporting data export and network monitoring.

[0032] Electrical box 2, sawing mechanism, anchor bolt feeding mechanism 5, clamping mechanism, sensors, and actuators are all electrically connected and interact with control console 7 to form a fully closed-loop automatic control system, which can complete anchor bolt straight cutting, arbitrary angle oblique cutting, fixed length batch cutting, continuous cyclic processing, automatic shutdown and alarm in case of abnormality.

[0033] The sawing drive and angle adjustment assembly is mounted on the back of the mounting bracket 3. This part is the core structure of the present invention that enables oblique cutting, and consists of a power transmission component, a turntable component, and a tension adjustment component.

[0034] Motor 301 is the main sawing motor, using a variable frequency speed control motor or a servo motor. It is fixedly mounted on the back of the mounting bracket 3. The output shaft is connected to the input shaft of the transmission box 302 via a coupling or key. The transmission box 302 uses a gear set or synchronous pulley to achieve speed reduction and reversal, smoothly transmitting power to the worm gear 304. The worm gear 304 is horizontally arranged, with both ends supported by bearings on the inner wall of the turntable box 303. The bearings are dustproof and sealed, and are lubricated with grease, requiring no maintenance for long-term operation.

[0035] The worm 304 and worm wheel 305 form a worm gear pair. The worm gear drive features self-locking, a large reduction ratio, smooth operation, low noise, and high torque. It can prevent the saw blade from reversing or slipping during sawing, ensure reliable locking of the bevel angle, and prevent angle deviation due to cutting force. The worm wheel 305 is interference-fitted or keyed onto the rotating shaft 306. The rotating shaft 306 is vertically arranged, and its upper and lower ends are also supported by bearings in the turntable housing 303. The middle part of the rotating shaft 306 is fixedly connected to the turntable 307. The turntable 307 is a high-strength aluminum alloy or steel wheel body, and a saw blade limiting groove is opened on the outer ring to prevent the saw blade 308 from running off-center or coming off the wheel.

[0036] The worm gear 305, worm 304, and rotating shaft 306 are all enclosed inside the turntable housing 303. Lubricating oil is added inside the housing to achieve sufficient lubrication and heat dissipation, extending the life of the transmission components. The turntable housing 303 is fixedly connected to the mounting bracket 3, and its position remains unchanged, serving as the reference for sawing power output.

[0037] The back of the mounting bracket 3 is movably connected to a turntable box 309. The bottom of the turntable box 309 is provided with a slide rail or groove, forming a sliding pair with the mounting bracket 3, which can move linearly in the horizontal direction. The back of the turntable box 309 is fixedly connected to a lead screw mechanism 310, which includes a lead screw, a nut, a support, and a scale. The right end of the lead screw is fixedly connected to a handwheel 311. The handwheel 311 has an anti-slip knurled texture and is equipped with an angle scale and a locking handle, which can realize coarse angle adjustment and precise positioning.

[0038] When the beveling angle needs to be adjusted, the operator rotates handwheel 311, causing the lead screw to rotate and move the nut and turntable box 309, changing the center distance between turntable box 303 and turntable box 309. This achieves two functions: first, it tensions the saw blade 308, ensuring it operates under appropriate tension and preventing slippage or breakage due to excessive looseness; second, it continuously adjusts the beveling angle, allowing for arbitrary setting within the range of 0°–45° to meet the requirements of anchor bolt beveling. After the angle adjustment is complete, the locking handle locks the lead screw position, keeping the beveling angle fixed and unchanged during processing.

[0039] Turntable 2 309 is rotatably connected to turntable 2 312 at its front end. Turntable 2 312 has the same structure as turntable 1 307. The saw blade 308 is simultaneously fitted into the limiting grooves of turntable 1 307 and turntable 2 312, forming a closed-loop sawing blade. After motor 2 301 starts, power is transmitted to turntable 1 307 through transmission box 302, worm gear 304, worm wheel 305, and rotating shaft 306, driving the saw blade 308 to rotate at high speed, realizing the cutting action on the anchor bolt.

[0040] To ensure smooth sawing, both turntable 307 and turntable 312 have undergone dynamic balancing. The saw blade 308 is a bimetallic wear-resistant band saw blade, with tooth profile and pitch designed to match the anchor rod diameter and material. The mounting frame 3 has internal sawing cooling and lubrication interfaces, allowing for the introduction of cutting fluid to reduce sawing temperature, minimize burrs, and extend saw blade life. When the saw blade breaks, loosens, or jams, the system identifies the abnormality through current detection or tension sensor, immediately stopping the machine and triggering an alarm to prevent equipment damage and safety accidents.

[0041] Mounting bracket 3 is fixedly mounted on guide rail 401 via connecting bracket 402. Guide rail 401 is a linear precision guide rail with surface hardening treatment, resulting in high hardness and good wear resistance. The bottom of retainer 4 slides with guide rail 401, allowing it to move freely along the length of guide rail 401 with low movement resistance and accurate positioning. Retainer 4 is used to support, limit, and stabilize saw blade 308 during sawing, preventing saw blade from shaking, swaying, or vibrating during high-speed operation, ensuring straight anchor bolt cuts, accurate angles, and smooth end faces.

[0042] The back of the retainer 4 is integrally formed or bolted to the adjusting block 404. The back of the adjusting block 404 has a groove 405. The groove 405 is a rectangular through groove with a smooth inner wall. Two clamping blocks 406 are slidably installed inside. The lower clamping block 406 is fixedly connected to the bottom of the groove 405 and remains in a fixed position. The upper clamping block 406 can slide up and down along the groove 405 to achieve the clamping and loosening of the middle cleaning block 407.

[0043] A threaded hole is formed on the upper surface of the adjusting block 404, and an adjusting bolt 408 is installed in the threaded hole. The bottom of the adjusting bolt 408 abuts against the upper surface of the upper clamping block 406. When the adjusting bolt 408 is rotated clockwise, it pushes the upper clamping block 406 downward, reducing the gap between the two clamping blocks 406, thereby clamping the cleaning block 407 and making the working surface of the cleaning block 407 tightly fit against both sides of the saw band 308. When the adjusting bolt 408 is rotated counterclockwise, the upper clamping block 406 returns to its original position under the elastic force of the cleaning block 407, and the cleaning block 407 is released and can be quickly removed and replaced.

[0044] The cleaning block 407 is made of wear-resistant, oil-absorbing, and lint-free non-woven fabric, felt, or sponge material. It has a tear-and-replace structure, is low-cost, and easy to replace. When the equipment is running, the saw blade 308 passes through the cleaning block 407 at high speed. The cleaning block 407 can wipe away iron filings, scale, oil, and cutting fluid residue from the surface of the saw blade in real time, preventing impurities from being carried into the saw wheel, scratching the anchor bolt surface, and accelerating saw blade wear. This significantly extends the service life of the saw blade while ensuring stable cut quality.

[0045] The retainer 4 can slide and move on the guide rail 401, remaining in the working position during normal processing to support and clean the saw blade. When the equipment is stopped for maintenance, saw blade replacement, or saw wheel inspection, the retainer 4 can be slid to a clearance position, providing ample operating space for convenient and safe maintenance. The adjusting bolt 408 allows for stepless adjustment of the clamping force, flexibly adjusting the clamping force according to the saw blade thickness and the wear degree of the cleaning block, ensuring cleaning effectiveness without hindering the normal operation of the saw blade.

[0046] The top of the electrical box 2 is equipped with an anchor bolt feeding mechanism 5, which is the key component for achieving fully automatic feeding in this invention. It can realize automatic anchor bolt advancement, adjustable feeding speed, adaptive feeding of anchor bolts of different diameters, and accurate feeding positioning.

[0047] The anchor bolt feeding mechanism 5 includes a mounting box, a hydraulic cylinder 501, mounting plate one 502, mounting plate two 503, a rotating wheel one 504, a rotating wheel two 505, and an adjuster 506. The mounting box is a welded steel plate structure, with its bottom slidably connected to the top of the electrical box 2. The sliding surface is lined with wear-resistant sliding plates, ensuring smooth operation without jamming. The hydraulic cylinder 501 is the feeding power element. The cylinder body is fixed to the back of the mounting box, and the piston rod is fixed to the electrical box 2 or the bracket 1. The hydraulic cylinder 501 is connected to the hydraulic system and its extension and retraction are controlled by a solenoid valve to realize the feeding and retraction actions. The hydraulic system is equipped with an overflow valve and a throttle valve to adjust the feeding pressure and feeding speed, ensuring smooth feeding without impact and without bending the anchor bolt.

[0048] Mounting plate 502 is fixed to the front of the mounting box, and its position is fixed. Mounting plate 503 is movably mounted on the other side, and it can move closer to or further away from mounting plate 502. A rotating wheel 504 is mounted on the front end of mounting plate 502, and a rotating wheel 505 is mounted on the front end of mounting plate 503. Both wheels have arc-shaped grooves on their surfaces, matching the outer diameter of the anchor bolt, effectively clamping the anchor bolt and reducing surface damage. The wheels are made of wear-resistant rubber or polyurethane material, with moderate friction, reliably feeding the anchor bolt without damaging the threads or outer wall.

[0049] The adjuster 506 employs a screw-type, gear-type, or quick-adjustment handle structure, connecting the mounting plate 503 to the mounting housing. Operators can quickly adjust the position of the mounting plate 503 according to the anchor bolt diameter, thereby changing the distance between the rotating wheels 504 and 505 to reliably clamp anchor bolts of different diameters. The adjustment range covers commonly used anchor bolt specifications, and it automatically locks in place after adjustment, preventing loosening during operation.

[0050] During operation, the anchor rod is placed between rotating wheel 504 and rotating wheel 505. Hydraulic cylinder 501 extends, pushing the mounting box forward. The rotating wheels drive the anchor rod smoothly towards the clamping and sawing mechanisms. The feed length is preset by control console 7, and precise length control is achieved with the help of a displacement sensor or encoder, resulting in minimal error and meeting the anchor rod cutting accuracy requirements. The feed automatically stops after reaching the desired position, waiting for sawing to complete. After sawing, hydraulic cylinder 501 retracts, the feed mechanism resets, and the next feeding cycle begins.

[0051] The electrical box 2 has a fixed clamping frame 8 on the front. The clamping frame 8 is a high-strength cast steel part with sufficient rigidity. It is used to install the main clamping component to realize the anchor rod's rapid centering, adaptive floating clamping, temperature monitoring, displacement monitoring, and automatic protection. It solves the problems of inaccurate centering, uneven clamping force, easy scratching of workpieces, and easy overheating and deformation of traditional clamping devices.

[0052] A clamping ring 801 is fixed to the front end of the clamping frame 8. The clamping ring 801 is an open circular ring structure with a through groove 802 on its outer circumference, giving it the ability to elastically contract and expand. An air pipe 804 is fixedly connected to the outer circumference of the clamping ring 801. The air pipe 804 is a rigid or flexible air pipe, with one end connected to the inner cavity of the clamping ring 801 and the other end connected to the output end of the air compressor inside the electrical box 2 via an air valve 805. The air valve 805 is an electrically controlled solenoid valve, controlled by the control console 7 to open and close the air passage.

[0053] An extendable telescopic rod 803 is movably installed inside the through groove 802. One end of the extendable rod 803 is connected to the air cavity inside the vent pipe 804, and the other end is fixedly connected to the pre-tightening ring 806. The pre-tightening ring 806 is made of highly elastic rubber or silicone, which has good extensibility and fit, and its inner diameter can adapt to the diameter of the anchor rod.

[0054] When centering and clamping are required, the control valve 805 on the control console 7 opens, allowing compressed air to enter the vent pipe 804. This pushes the telescopic rod 803 to extend, causing the clamping ring 801 to contract. Simultaneously, the pre-tightening ring 806 contracts, and its inner wall quickly clamps the outer circumference of the anchor rod, achieving automatic centering without eccentricity or skewing. This ensures the anchor rod axis is perpendicular to the sawing direction or at a set angle, fundamentally improving the accuracy of the cutting angle and length. When releasing, the air valve 805 releases air, the telescopic rod 803 retracts under elastic force, and the pre-tightening ring 806 expands, allowing the anchor rod to be freely fed or discharged.

[0055] A circular groove 8061 is formed inside the preload ring 806. The circular groove 8061 is arranged in a closed manner along the circumference. An axial preload cylinder 8062 is fixedly installed inside. The axial preload cylinder 8062 is a miniature thin cylinder with fast action response and stable thrust. The output end of the axial preload cylinder 8062 is connected to the preload shaft 8063. A connecting rod 8064 is fixedly fixed to the top of the preload shaft 8063. The upper end of the connecting rod 8064 is fixedly connected to the locking plate 807. The lower surface of the locking plate 807 slides against the upper surface of the preload ring 806.

[0056] The locking plate 807 has an integrally formed hinge joint 808 at its top. A sliding groove is formed inside the hinge joint 808, within which a hinge shaft 809 is slidably installed. The hinge shaft 809 can rotate and slide slightly within the hinge joint 808. A floating clamping plate 810 is fixedly connected to the outside of the hinge shaft 809. The floating clamping plate 810 is an arc-shaped plate, with a polytetrafluoroethylene (PTFE) wear-resistant layer 8104 fixed near the anchor rod. The PTFE wear-resistant layer 8104 has a low coefficient of friction, is heat-resistant, non-stick, and does not damage the workpiece, effectively reducing the resistance during anchor rod feeding while ensuring stable clamping.

[0057] When the axial preload cylinder 8062 is activated, it pushes the preload shaft 8063, connecting rod 8064, and locking plate 807 forward. Through the hinge joint 808 and hinge shaft 809, it drives the floating clamping plate 810 to press against the anchor bolt. Because the hinge structure can swing and shift slightly, the floating clamping plate 810 can adaptively conform to the surface of the anchor bolt. Regardless of whether the anchor bolt has slight bending, ellipticity, or eccentricity, it can achieve uniform clamping across the entire contact surface, avoiding excessive local pressure that could lead to anchor bolt deformation, indentation, or thread damage.

[0058] A sensor slot is provided at the center of the floating clamp 810, and a displacement sensor 8101 is fixedly installed in the slot. The displacement sensor 8101 is a contact or non-contact sensor that detects the displacement, swing amplitude and moving distance of the locking plate 807 of the floating clamp 810 in real time, reflecting the anchor clamping status, feeding status and bending degree.

[0059] The floating clamp 810 has mounting grooves 8102 at both ends, and a temperature sensor 8103 is fixed inside the mounting groove 8102. The temperature sensor 8103 is arranged in close contact with the polytetrafluoroethylene wear-resistant layer 8104 to monitor the temperature change in the contact area between the floating clamp 810 and the anchor bolt in real time. During the sawing and feeding process, the anchor bolt will generate heat due to friction. If the temperature is too high, it will cause changes in the metallographic structure of the anchor bolt, deformation, and a decrease in hardness, affecting the support performance.

[0060] This invention sets a safe temperature threshold of 60°C. When the temperature sensor 8103 detects that the temperature of the contact area exceeds 60°C, it immediately sends a signal to the control console 7, and the control system executes three-level protection actions: First, it automatically reduces the pneumatic clamping force and the thrust of the axial preload cylinder to reduce frictional heat generation; second, it starts the external air cooling device or the cutting fluid cooling device to force cooling; third, if the temperature continues to rise, it immediately stops the machine and alarms, waiting for manual inspection to completely avoid thermal deformation of the workpiece.

[0061] The displacement sensor 8101 is set with an upper limit for displacement. When it detects that the moving distance of the locking plate 807 exceeds the limit or the swing of the floating clamp 810 exceeds the tolerance, it is determined that the anchor rod is bent too much, the clamping is abnormal or the feed is stuck. The control system immediately controls the axial pre-tightening cylinder 8062 to move, push the pre-tightening shaft 8063 and the connecting rod 8064 to reset, so that the floating clamp 810 returns to the normal clamping position. At the same time, the feed is paused to avoid overloading the equipment, damaging the saw blade or bending the anchor rod.

[0062] To further improve the stability of long and large-diameter anchor rods during sawing and prevent them from vibrating, shifting, or swinging under sawing force, this device is equipped with an additional screw-driven auxiliary clamping mechanism on the front of the electrical box 2. This mechanism works in conjunction with the main clamping mechanism to form a double clamping positioning, significantly improving the processing accuracy of long materials.

[0063] The auxiliary clamping mechanism consists of a motor 9, a reducer 901, a lead screw frame 902, a lead screw 903, a lead screw nut 904, a movable clamping plate 905, and a fixed clamping plate 906. The lead screw frame 902 is a gantry-type frame structure, fixed to the front of the electrical box 2, and is rigid and non-deformable. The motor 9 is fixedly installed on the right side of the lead screw frame 902. The output shaft of the motor 9 is connected to the reducer 901. The output shaft of the reducer 901 is connected to the lead screw 903 by a key or coupling. The lead screw 903 is arranged horizontally and supported at both ends by bearings on the lead screw frame 902.

[0064] A screw nut 904 is installed on the screw rod 903. The screw nut 904 is fixedly connected to the movable clamping plate 905, which can move left and right along the guide rail of the screw rod frame 902. A fixed clamping plate 906 is fixed on the left side of the screw rod frame 902. The fixed clamping plate 906 remains in place and is arranged opposite to the movable clamping plate 905. Both have arc-shaped clamping openings on their inner sides, which match the diameter of the anchor rod.

[0065] During operation, motor 9 starts, and after being reduced in speed and torque by reducer 901, it drives lead screw 903 to rotate. Lead screw 903 drives lead screw nut 904 and movable clamping plate 905 to move towards fixed clamping plate 906, clamping the anchor bolt between them, achieving secondary positioning and reinforcement. The lead screw drive has self-locking properties, preventing loosening after clamping, and the clamping force is stable and reliable, capable of withstanding large sawing forces. Motor 9 uses forward and reverse rotation control, enabling rapid clamping, slow clamping, and release / reset, providing flexible operation.

[0066] The auxiliary clamping mechanism can be activated or deactivated depending on the length of the anchor bolt. Short anchor bolts can use only the main clamping mechanism, while long anchor bolts and large-diameter anchor bolts can use both the main clamping and auxiliary clamping mechanisms simultaneously, making it widely applicable and highly flexible.

[0067] After the equipment is powered on, the control console 7 automatically performs self-checks on the sensors, actuators, air circuits, hydraulics, and motors. If there are no faults, it enters the standby interface. The operator sets parameters such as anchor length, processing quantity, beveling angle, feed speed, clamping force, and temperature threshold on the touch screen.

[0068] The anchor rod is placed between roller 504 and roller 505 of the anchor rod feeding mechanism 5. The adjuster 506 automatically or manually adjusts the roller spacing to ensure the anchor rod is reliably clamped. The control console 7 opens the control valve 805, and compressed air pushes the telescopic rod 803, causing the pre-tensioning ring 806 to retract and tighten the anchor rod, achieving rapid automatic centering and ensuring accurate anchor rod axis.

[0069] Axial pre-tightening cylinder 8062 is activated, and floating clamping plate 810 adaptively conforms to the surface of anchor rod; simultaneously, motor 9 drives auxiliary clamping mechanism to operate, and movable clamping plate 905 and fixed clamping plate 906 clamp the anchor rod a second time. If a bevel cut is required, turn handwheel 311 to adjust the position of turntable box 309, set the bevel cut angle and lock it; for a straight cut, keep the 0° position.

[0070] Hydraulic cylinder 501 starts, pushing the anchor rod precisely to the sawing position, and automatically stops after reaching the position. Motor 301 starts, and saw blade 308 rotates at high speed to cut the anchor rod; the saw blade works synchronously with the cleaning mechanism to clean the saw blade in real time and stabilize the sawing.

[0071] Displacement sensor 8101 and temperature sensor 8103 collect data in real time, and automatically execute protection actions in case of over-temperature, over-displacement, or overload to ensure processing safety. After sawing to the desired position, motor 301 stops, and the saw band stops running; the main clamping mechanism and the auxiliary clamping mechanism release in sequence, and the cut anchor rod falls into the discharge platform 6 by its own weight and slides to the collection position.

[0072] The feed mechanism returns to its original position, and the equipment automatically enters the next cycle until the set processing quantity is completed. After processing is completed, the equipment automatically stops. The retainer 4 can be manually slid to replace the cleaning block 407, check the saw band tension, and clean up iron filings and debris to prepare for the next production.

[0073] Control logic: The control console 7 has a built-in PLC programmable logic controller. All actions are executed in a preset program sequence and are equipped with interlock protection: no feeding if not clamped, no sawing if not in position, no loosening during sawing, and a complete shutdown in case of an abnormality. It can switch to manual mode for debugging, maintenance, and single-step operation, and automatic mode for batch production.

[0074] Safety protection functions: Emergency stop protection: Pressing the emergency stop button from any position will immediately stop all actions and reset the power supply.

[0075] Over-temperature protection: Automatically reduces power, cools down, and shuts down when the temperature exceeds 60℃.

[0076] Displacement over-limit protection: Automatic reset and alarm in case of abnormal clamping displacement.

[0077] Saw belt fault protection: Automatic shutdown in case of saw belt breakage, jamming, or overload.

[0078] Clamping incomplete protection: If reliable clamping is not detected, feeding and sawing are prohibited.

[0079] Overload protection: Automatic protection against motor overload, hydraulic overload, and pneumatic overload.

[0080] Routine maintenance points Regularly check the saw blade tension and wear, and replace it promptly.

[0081] Replace cleaning block 407 immediately when it gets dirty to ensure cleaning effectiveness.

[0082] Regularly lubricate the worm gear box, bearings, and lead screw with grease.

[0083] Check for leaks in the air and hydraulic lines, and drain the filters regularly.

[0084] Clean the sensor surface to prevent iron filings and dust from affecting accuracy. It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0085] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automatic anchor bolt cutting production device with a bevel-cutting band saw, comprising a support (1), an electrical box (2), a mounting frame (3), a sawing mechanism, an anchor bolt feeding mechanism (5), a clamping mechanism, a discharge platform (6), and a control console (7), characterized in that: The mounting frame (3) is equipped with an adjustable sawing angle oblique cutting drive assembly. The sawing mechanism includes a saw blade (308) and a matching saw blade holding and cleaning assembly. The anchor feed mechanism (5) can be adapted to automatically feed anchors of different diameters. The clamping mechanism is equipped with floating clamping and temperature and displacement monitoring components to realize adaptive centering clamping and overheat protection of the anchor. The electrical box (2), sawing mechanism, feed mechanism and clamping mechanism are all electrically connected to the control console (7) to realize fully automatic unloading and oblique cutting control.

2. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability according to claim 1, characterized in that: The oblique cutting drive assembly includes a second motor (301), a transmission box (302), a turntable box (303), a worm (304), a worm wheel (305), a rotating shaft (306), a turntable (307), a turntable box (309), a lead screw mechanism (310), and a handwheel (311). The second motor (301) drives the worm (304) and the worm wheel (305) through the transmission box (302), which in turn the turntable (307) rotates. The distance of the turntable box (309) is adjusted by the lead screw mechanism (310) and the handwheel (311). The turntable (307) and the turntable (312) tension the saw blade (308) to achieve the adjustment of the sawing and oblique cutting angles.

3. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability as described in claim 1, characterized in that: The saw band holding and cleaning assembly includes a retainer (4), a guide rail (401), a connecting frame (402), an adjusting block (404), a clamping block (406), a cleaning block (407), and an adjusting bolt (408). The retainer (4) slides along the guide rail (401), and the adjusting block (404) drives the clamping block (406) to clamp the cleaning block (407) through the adjusting bolt (408). The cleaning block (407) contacts the saw band (308) to achieve online cleaning and replacement.

4. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability according to claim 1, characterized in that: The anchor bolt feeding mechanism (5) includes a hydraulic cylinder (501), a mounting plate one (502), a mounting plate two (503), a rotating wheel one (504), a rotating wheel two (505), and an adjuster (506); the adjuster (506) adjusts the position of the mounting plate two (503) and changes the distance between the rotating wheel one (504) and the rotating wheel two (505) to adapt to anchor bolts of different diameters, and the hydraulic cylinder (501) drives the feeding action.

5. The fully automatic anchor bolt cutting production device of the band saw type with oblique cutting capability according to claim 1, characterized in that: The clamping mechanism includes a clamping frame (8), a clamping ring (801), a through groove (802), a telescopic rod (803), a vent pipe (804), an air valve (805), a pre-tightening ring (806), a locking plate (807), a floating clamping plate (810), a displacement sensor (8101), and a temperature sensor (8103). The vent pipe (804) vents air to drive the telescopic rod (803) so that the pre-tightening ring (806) is centered and clamps the anchor rod. The floating clamping plate (810) is provided with a polytetrafluoroethylene wear-resistant layer (8104). The displacement sensor (8101) monitors the clamping displacement, and the temperature sensor (8103) monitors the contact temperature. When the temperature exceeds the limit, the clamping force is reduced and air cooling is activated.

6. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability according to claim 5, characterized in that: The pre-tightening ring (806) is provided with an annular groove (8061), an axial pre-tightening cylinder (8062), a pre-tightening shaft (8063), and a connecting rod (8064); the axial pre-tightening cylinder (8062) drives the pre-tightening shaft (8063) and the connecting rod (8064), thereby driving the locking plate (807) and the floating clamp (810) to achieve adaptive floating clamping and automatic reset when the displacement exceeds the limit.

7. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability according to claim 1, characterized in that: It also includes an auxiliary clamping mechanism consisting of a motor (9), a reducer (901), a lead screw frame (902), a lead screw (903), a lead screw nut (904), a movable clamping plate (905), and a fixed clamping plate (906); the motor (9) drives the lead screw (903) through the reducer (901), which drives the movable clamping plate (905) to move, and cooperates with the fixed clamping plate (906) to achieve auxiliary clamping and positioning of the anchor rod.

8. The fully automatic anchor bolt cutting production device of the band saw type with oblique cutting capability according to claim 2, characterized in that: The worm (304), worm wheel (305), and rotating shaft (306) are integrated in turntable box one (303). The relative positions of turntable box one (303) and turntable box two (309) are adjustable, so as to realize continuous adjustment of the tension and oblique cutting angle of the saw band (308).

9. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability according to claim 3, characterized in that: The cleaning block (407) is a tear-off and replaceable structure. The adjusting bolt (408) enables stepless adjustment of the clamping force. The retainer (4) can slide along the guide rail (401) to switch between shutdown maintenance and online cleaning.

10. The fully automatic anchor bolt blanking production device of the band saw type with oblique cutting capability according to claim 1, characterized in that: The control console (7) integrates a PLC control unit, receives signals from the displacement sensor (8101) and the temperature sensor (8103), and automatically controls the feed speed, clamping force, sawing speed and oblique cutting angle to realize fully automatic fixed length, straight cutting and oblique cutting of anchor rods.

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