Control method of a cutting device and cutting device

Abstract

The application provides a control method of a cutting device, the cutting device comprising a cutting line, a tension detection unit and a diameter detection unit; the method comprising: detecting a tension value of the cutting line by the tension detection unit during the cutting process of the cutting device; detecting a diameter value of the cutting line by the diameter detection unit; determining a broken line risk index corresponding to the cutting line according to the tension value and the diameter value, the broken line risk index being used to represent a broken line probability of the cutting line in a current state; and controlling the cutting device according to the broken line risk index. The application directly and real-timely detects two physical parameters of dynamic tension and diameter in the running process of the cutting line, and automatically controls the cutting device to make adjustment according to the detection result, so that active intervention on the broken line risk of the cutting line is realized, and the stability and safety of the cutting process are improved.

Description

Technical Field

[0001] This invention relates to the field of semiconductor technology, and more specifically to a control method for a cutting device and the cutting device itself. Background Technology

[0002] Multi-wire cutting equipment is currently the mainstream core equipment for cutting hard and brittle materials such as semiconductor ingots. Its working principle involves using a high-speed reciprocating cutting wire carrying cutting slurry to grind and cut the hard and brittle materials. The cutting wire, as the core consumable directly performing the cutting task, directly determines the success or failure of the cutting process, product yield, and manufacturing costs. A roll of industrial-grade cutting steel wire can typically be over 500 kilometers long and needs to be used continuously for extended periods during the cutting process. During this time, it must withstand high-frequency reciprocating tension, grinding wear, and complex impact conditions, making it highly susceptible to wire breakage, which can lead to a series of production problems.

[0003] However, in actual production, the risk of wire breakage cannot be effectively identified in advance. It can only be dealt with passively after the wire breakage accident occurs. Wire breakage accidents not only cause the scrapping of the entire valuable crystal rod, but also lead to production process interruption, time-consuming equipment maintenance, and reduced cutting efficiency. Summary of the Invention

[0004] In view of this, embodiments of the present invention aim to provide a control method for a cutting device and a cutting device, so as to solve the problem that the risk of wire breakage in the prior art cannot be effectively identified.

[0005] This invention provides a cutting device, which includes a cutting wire, a tension detection unit, and a diameter detection unit. The method includes: During the process of cutting materials by the cutting equipment, the tension value of the cutting line is detected by the tension detection unit; The diameter value of the cutting line is detected by the diameter detection unit. Based on the tension value and the diameter value, the breakage risk index corresponding to the cutting wire is determined. The breakage risk index is used to characterize the probability of the cutting wire breaking in the current state. The cutting equipment is controlled according to the wire breakage risk index.

[0006] In one embodiment, controlling the cutting equipment based on the wire breakage risk index includes: Determine the target control strategy corresponding to the aforementioned disconnection risk index; The cutting equipment is controlled based on the target control strategy.

[0007] In one embodiment, the wire breakage risk index includes a wire breakage risk level, and determining the wire breakage risk index corresponding to the cutting wire based on the tension value and the diameter value includes: If the tension value and the diameter value satisfy at least one of the following conditions, then the breakage risk level of the cutting wire is determined to be the first risk level: The tension value is greater than the first tension threshold and less than or equal to the second tension threshold; The tension value is greater than the second tension threshold and less than the third tension threshold, and the duration of maintenance is less than the first duration; The diameter value is less than the first diameter threshold and greater than or equal to the second diameter threshold; The diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration during which the diameter value is less than the second diameter threshold is less than the second duration; The determination of the target control strategy corresponding to the disconnection risk index includes: If the breakage risk level is the first risk level, the first control strategy among the preset multiple control strategies is used to determine the target control strategy corresponding to the breakage risk level. The first control strategy includes controlling the cutting device to output early warning information, which is used to indicate that there is a breakage risk in the cutting wire.

[0008] In one embodiment, determining the breakage risk index corresponding to the cutting wire based on the tension value and the diameter value includes: If the tension value and the diameter value satisfy at least one of the following conditions, then the breakage risk level of the cutting wire is determined to be the second risk level: The tension value is greater than the second tension threshold and less than the third tension threshold, and the duration of maintenance is greater than or equal to the first duration; The diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration is greater than or equal to the second duration; The determination of the target control strategy corresponding to the disconnection risk index includes: If the risk level of the wire breakage is the second risk level, the second control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of the wire breakage. The second control strategy includes controlling the cutting equipment to reduce the tension value of the cutting wire and / or reduce the wire travel speed of the cutting wire.

[0009] In one embodiment, determining the breakage risk index corresponding to the cutting wire based on the tension value and the diameter value includes: If the tension value and the diameter value satisfy at least one of the following conditions, then the breakage risk level of the cutting wire is determined to be the third risk level: The tension value is greater than the third tension threshold; The diameter value is less than the third diameter threshold; The determination of the target control strategy corresponding to the disconnection risk index includes: If the risk level of the wire breakage is the third risk level, the third control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of the wire breakage. The third control strategy includes controlling the cutting equipment to stop operating.

[0010] In one embodiment, the control method further includes: If the cutting device outputs a warning message, then the historical tension value and historical diameter value of the cutting line are obtained within a specified time period before and after the cutting device outputs the warning message; The second tension threshold and the second diameter threshold are updated based on the historical tension value and the historical diameter value.

[0011] In one embodiment, the tension detection unit and the diameter detection unit are disposed at a target position in the cutting device to simultaneously detect the tension value and diameter value at the same point on the cutting line.

[0012] In one embodiment, the target location includes the area between the wire feeding port and the wire feeding guide wheel of the cutting chamber in the cutting device, and / or the area between the wire taking-up port and the wire taking-up guide wheel of the cutting chamber in the cutting device, wherein the wire feeding guide wheel is used to feed the cutting wire into the cutting chamber, and the wire taking-up guide wheel is used to feed the cutting wire out of the cutting chamber.

[0013] In one embodiment, detecting the tension value of the cutting wire by the tension detection unit includes: The tension detection unit is controlled to detect the tension value of the cutting line based on a first frequency; The step of detecting the diameter value of the cutting line by the diameter detection unit includes: The diameter detection unit is controlled to detect the diameter value of the cutting line based on a second detection frequency; Both the first frequency and the second detection frequency are greater than or equal to 1 kHz.

[0014] In one embodiment, the second tension threshold is 40% of the breaking tensile force of the cutting wire; The second diameter threshold is 95% of the nominal diameter of the cutting line.

[0015] Another aspect of the present invention provides a cutting device, which includes a cutting wire, a tension detection unit, a diameter detection unit, and a controller. The tension detection unit is configured to detect the tension value of the cutting line during the process of the cutting equipment cutting the material; The diameter detection unit is configured to detect the diameter value of the cutting line during the process of the cutting equipment cutting the material; The controller is configured as follows: Receive the tension value and the diameter value; Based on the tension value and the diameter value, the breakage risk index corresponding to the cutting wire is determined. The breakage risk index is used to characterize the probability of the cutting wire breaking in the current state. The cutting equipment is controlled according to the wire breakage risk index.

[0016] Compared with related technologies, the cutting equipment control method provided by the present invention has the following advantages: The control method for the cutting equipment provided by this invention uses a tension detection unit and a diameter detection unit to detect the tension and diameter values ​​of the cutting wire in real time during operation. Based on the combined results of these two measurements, a dynamic wire breakage risk index is generated. This index can accurately predict the probability of wire breakage under the current operating conditions. The controller then controls the cutting equipment according to the wire breakage risk index, allowing the equipment to proactively adjust cutting parameters or trigger early warning protection based on the real-time risk index. This effectively avoids accidental wire breakage caused by sudden tension changes or wire wear, significantly improving the stability and safety of the cutting process, extending the service life of the cutting wire, reducing material scrap and downtime, and ensuring cutting quality and production efficiency. Attached Figure Description

[0017] Figure 1 The diagram shown is a flowchart illustrating a control method for a cutting device according to an embodiment of the present invention.

[0018] Figure 2 The diagram shown is a structural schematic of a cutting device provided in an embodiment of the present invention.

[0019] Figure 3 The diagram shown is a structural schematic of another cutting device provided in an embodiment of the present invention.

[0020] Figure 4 The diagram shows a system architecture diagram of the control method for a cutting device provided in an embodiment of the present invention.

[0021] Figure 5 The diagram shown is an implementation flowchart of a control method for a cutting device provided in an embodiment of the present invention.

[0022] Figure 6 The diagram shown is a block diagram of an electronic device provided in an embodiment of the present invention. Detailed Implementation

[0023] 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.

[0024] In the description of the embodiments of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0025] In the field of cutting equipment technology, to monitor the operating status and prevent breakage of cutting steel wire (hereinafter referred to as cutting wire or steel wire), the common practice is to indirectly estimate the steel wire tension through motor current feedback and rely on human experience to observe and judge the cutting process. Specifically, this solution indirectly reflects changes in steel wire tension by monitoring the current of the take-up and untake-down motors. Its basic working principle is to calculate the tension value of the steel wire based on the correspondence between current and torque. It is widely used mainly because it can achieve basic tension control adjustment without adding additional sensing hardware, meeting the simple needs of conventional cutting conditions.

[0026] However, this solution performs poorly when applied to complex processes like multi-wire cutting of hard and brittle materials, which involves high speed, high load, and a closed cutting environment. A fundamental contradiction lies in the fact that the solution employs an indirect estimation method to reduce sensor configuration costs. Its inherent design inevitably compromises the real-time performance and accuracy of tension measurement, potentially even leading to wire breakage. Specifically, when cutting single-crystal silicon ingots, when the steel wire experiences millisecond-level tension spikes due to localized hard point impacts, the motor current feedback exhibits significant response lag, failing to reflect the true tension state in a timely manner. This results in the inability to identify the risk of wire breakage in advance, ultimately rendering the entire ingot unusable.

[0027] In practical application, the applicant found that the root causes of the aforementioned contradictions are multifaceted. From the perspective of detection principles, motor current feedback is an indirect measurement, as the signal must pass through multiple stages such as mechanical transmission and electrical response, resulting in phase lag and noise interference, making it impossible to capture millisecond-level tension mutations. From the perspective of physical parameters, related technologies only focus on the tension dimension, ignoring the key strength indicator of local diameter changes in the steel wire, and failing to identify local strength weakening caused by wear or original defects. From the perspective of system architecture, the lack of a dual-parameter synchronous monitoring and closed-loop control mechanism for the operating status of the steel wire means that the risk of wire breakage can only be addressed passively after the fact.

[0028] In view of the above problems, one embodiment of the present invention provides a control method for a cutting device. The cutting device includes a cutting wire, a tension detection unit, and a diameter detection unit. The cutting device may further include a controller, and the control method for the cutting device can be applied to the aforementioned controller, such as... Figure 1 As shown, the control method includes: 110. During the process of cutting materials by the cutting equipment, the tension value of the cutting line is detected by the tension detection unit.

[0029] 120. The diameter value of the cutting line is detected by the diameter detection unit.

[0030] 130. Based on the tension value and diameter value, determine the breakage risk index corresponding to the cutting wire. The breakage risk index is used to characterize the probability of the cutting wire breaking in the current state.

[0031] 140. Control the cutting equipment according to the wire breakage risk index.

[0032] The tension detection unit can refer to any sensor or combination of sensors capable of directly or indirectly measuring the dynamic tension on a steel wire. Specifically, it can refer to a miniature roller-type tension sensor with high dynamic response, which calculates the tension value by detecting the pressure exerted on the roller by the steel wire as it passes over it. Optionally, the tension detection unit can also include, but is not limited to: tension sensors based on strain gauge principles, force sensors based on piezoelectric effects, or force sensors based on electromagnetic force balance principles. Regardless of the form, its core function is to output an electrical signal characterizing the tension of the steel wire in real time at a sufficiently high frequency (e.g., not less than 1 kHz) during the operation of the steel wire.

[0033] The diameter detection unit can refer to any device or system capable of measuring the local outer diameter of a steel wire in a non-contact manner during its operation. Specifically, it can refer to a high-precision laser micrometer that emits a laser beam to scan the steel wire through its field of view, calculating the outer diameter by analyzing obstruction or reflection signals. Optionally, the diameter detection unit can also include, but is not limited to: an optical measurement system based on a charge-coupled device (CCD) image sensor, a micro-displacement sensor array based on the eddy current principle, or a ranging device based on the ultrasonic principle. Its core function is to output the local diameter value of the current measurement point of the steel wire in real time at a frequency of not less than 1 kHz during its operation, with measurement accuracy capable of resolving diameter changes at the micrometer level (e.g., attenuation from a standard diameter of 120 micrometers to 115 micrometers).

[0034] In this context, a controller can refer to any programmable electronic device capable of receiving signals from one or more sensors, processing and logically analyzing these signals, and outputting control commands according to a preset algorithm. For example, a controller can be a high-performance industrial programmable logic controller, a dedicated embedded microprocessor system, or a hybrid control board integrating a digital signal processor and a logic controller. The core function of a controller is to perform operations on input data (such as filtering, comparison, and logical judgment) and output analog or digital commands to drive actuators.

[0035] For example, such as Figure 2 As shown, Figure 2 The diagram shown is a structural schematic of a cutting device according to an embodiment of this application. In addition to the cutting wire (e.g., steel wire), tension detection unit, diameter detection unit, and controller described above, the cutting device may also include an execution mechanism. The execution mechanism may include a motor for providing cutting power, multiple guide wheel groups for guiding and supporting the steel wire, and a wire feeding mechanism and a wire take-up mechanism for controlling the wire feeding speed and providing basic tension.

[0036] Optionally, such as Figure 3 As shown, a set of detection units (such as...) can be set up on the path of the steel wire before it enters the cutting chamber by the wire feeding mechanism and on the path of it being retrieved by the wire take-up mechanism after exiting the cutting chamber. Figure 3The system comprises a first group of detection units and a second group of detection units. Each group of detection units includes at least one tension detection unit and one diameter detection unit. Optionally, the tension detection unit and the diameter detection unit can be installed at the same or adjacent physical locations to ensure that they can measure the physical state of approximately the same point on the steel wire. The signal output terminals of both the tension detection unit and the diameter detection unit are connected to the controller. The controller integrates a signal processing module, a data processing and analysis module, and an instruction output module. Its output terminals are connected to the main control system of the cutting equipment and the actuators, including but not limited to servo motors controlling the propulsion force and drive mechanisms controlling the wire speed. This constitutes a complete real-time closed-loop control loop consisting of a sensing unit, a decision control unit, and an execution unit.

[0037] In practical applications, during the process of cutting materials by the cutting equipment, the tension value of the cutting line is detected by the tension detection unit, and the diameter value of the cutting line is detected by the diameter detection unit.

[0038] In some implementations, the tension detection unit can employ a high-dynamic-response miniature tension sensor, directly mounted near the point of contact between the steel wire and the guide wheel, such as in the area where the steel wire contacts the guide wheel at the wire feeding or take-up point of the cutting chamber. The mounting bracket for the miniature tension sensor can be designed to minimize interference with the original steel wire path, avoiding any impact on cutting accuracy. This miniature tension sensor can measure the dynamic tension of the steel wire in real time at a frequency of at least 1 kHz, accurately capturing instantaneous tension spikes that may occur during the cutting process, lasting only a few milliseconds. Simultaneously, the diameter detection unit can employ a non-contact, high-precision laser micrometer, mounted on the same compact bracket as the tension sensor, ensuring that its measurement position is adjacent to or coincides with the measurement point of the tension sensor. This laser micrometer also scans the outer diameter of the steel wire passing through its measurement area at a frequency of at least 1 kHz, accurately identifying localized diameter reductions that are not visible to the naked eye due to long-term grinding wear or defects in the original material, such as microscopic diameter changes from a standard 120 micrometers to 115 micrometers or less.

[0039] Subsequently, the controller can receive signals from the tension detection unit and the diameter detection unit. The controller can either directly receive the raw electrical signals from the tension detection unit and the diameter detection unit, or it can receive digital signals that have undergone preliminary conversion by the front-end processing unit.

[0040] In some implementations, taking the original electrical signal as an example, the controller can filter and reduce noise on the original signal, for example, by using a low-pass filter to filter out high-frequency mechanical vibration noise, and then using a calibration algorithm to convert the electrical signal into real-time tension and real-time diameter values ​​with actual physical units.

[0041] Subsequently, the controller can control the cutting equipment based on the processed real-time tension and diameter values. Specifically, the controller can connect to the equipment's actuators via its own digital or analog output ports, such as a servo drive or hydraulic adjustment system that controls the wire tension. At the logic level, the controller has a pre-set risk assessment algorithm. For example, this algorithm first compares the real-time tension value with a preset tension safety threshold and the real-time diameter value with a preset diameter safety threshold. When any parameter, or both parameters simultaneously, exceed their respective safety threshold ranges, the controller outputs a corresponding control command. This command can be an analog signal used to adjust equipment operating parameters (such as reducing the tension setpoint or wire speed) or a switching signal that directly triggers the equipment to stop.

[0042] As can be seen, in this embodiment, by simultaneously introducing a tension detection unit and a diameter detection unit into the cutting equipment, the tension and diameter values ​​of the cutting wire during operation are directly detected at high frequency in real time. These two physical parameters are used as control inputs, and the controller automatically adjusts the operating parameters of the cutting equipment based on the detection results. This effectively improves the timeliness and accuracy of wire breakage risk warning without significantly increasing system complexity, thus preventing wire breakage accidents. Therefore, a closed-loop control system based on real-time dual-parameter monitoring is provided to solve the problems of black-box steel wire condition monitoring and lack of wire breakage warning in related technologies, achieving proactive intervention and early prevention of wire breakage risks.

[0043] In some implementations, the specific implementation of controlling the cutting equipment based on the wire breakage risk index in step 130 may include: Determine the target control strategy corresponding to the line disconnection risk index.

[0044] The cutting equipment is controlled based on a target control strategy.

[0045] Optionally, the breakage risk index may include a breakage risk level. Optionally, the breakage risk index may include a specific numerical value, for example, a higher value indicates a greater probability of the cutting line breaking in the current state. Optionally, this value can be a value from 0 to 100, or a percentage from 0% to 100%, without limitation.

[0046] Considering that not all deviations from normal operating conditions require immediate shutdown—for example, a brief tension spike may quickly disappear on its own, while a sustained, minute reduction in diameter requires attention but does not necessarily necessitate an immediate production halt—this embodiment classifies risks so that the controller can employ different control strategies for different levels of breakage risk. This effectively controls breakage risks while maximizing production continuity.

[0047] As an example, a fuzzy logic-based inference engine can be used, which takes tension and diameter values ​​as inputs and directly outputs the risk level through a pre-defined fuzzy rule base.

[0048] As another example, a model based on a machine learning classifier (such as a support vector machine or decision tree) can be used to determine the breakage risk level of the cutting wire based on the tension and diameter values. This model, trained on historical alarm data, can directly classify real-time input tension and diameter value pairs and output labels corresponding to the breakage risk level. Specifically, the controller first acquires the processed real-time tension and diameter values. Then, this pair of values ​​is input into a pre-stored risk discrimination rule, which defines different risk level ranges for different combinations of values. For example, a two-dimensional "tension-diameter" risk state plane is defined, where different regions correspond to different risk levels (e.g., low, medium, high). The current risk level is determined based on the region the value falls into. After acquiring the risk level, the controller can query and select the target control strategy corresponding to that level from a pre-built control strategy library. This strategy library can be a lookup table that maps "first risk level" to "first control strategy" (such as issuing only a warning message), "second risk level" to "second control strategy" (such as slightly reducing speed or tension), and "third risk level" to "third control strategy" (such as emergency shutdown). Finally, the controller can output the specific instructions needed to execute the target control strategy, and the intervention is completed through the actuator.

[0049] As can be seen, in this embodiment, by adopting the above-mentioned graded response control strategy, this preferred solution can take intervention measures of different strengths according to the severity of the risk. This further helps to solve the problem of how to effectively deal with the risk of line breakage of different severity while ensuring production continuity. Thus, it synergistically strengthens the core technical effect of the present invention in improving the intelligence level of equipment and production stability by actively and accurately intervening in the risk of line breakage.

[0050] In some implementations, taking the breakage risk index, which includes breakage risk levels, as an example, the step "determine the breakage risk index corresponding to the cutting wire based on the tension value and diameter value" includes: If the tension value and diameter value meet at least one of the following conditions, the breakage risk level of the cutting wire is determined to be the first risk level: The tension value is greater than the first tension threshold and less than or equal to the second tension threshold; The tension value is greater than the second tension threshold and less than the third tension threshold, and the duration of maintenance is less than the first duration; The diameter value is less than the first diameter threshold and greater than or equal to the second diameter threshold; The diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration of the diameter value being less than the second diameter threshold is less than the second duration; Accordingly, the specific implementation of the step "determining the target control strategy corresponding to the disconnection risk index" may include: If the risk level of wire breakage is the first risk level, the first control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of wire breakage. The first control strategy includes controlling the cutting equipment to output early warning information, which is used to indicate that there is a risk of wire breakage in the cutting wire.

[0051] For example, the risk level includes at least a first risk level. The conditions for the controller to determine a risk level as first include: a tension value greater than a first tension threshold and less than or equal to a second tension threshold; or a tension value greater than a second tension threshold and less than a third tension threshold, and a duration less than a first duration; or a diameter value less than a first diameter threshold and greater than or equal to a second diameter threshold; or a diameter value less than a second diameter threshold and greater than a third diameter threshold, and a duration less than a second duration. Meeting any one of these conditions constitutes a first risk level. When the risk level is determined to be first, the corresponding target control strategy is a first control strategy, which includes controlling the cutting equipment to output warning information to indicate the current risk of wire breakage.

[0052] The first tension threshold can refer to the tension value recorded when the cutting wire is in a normal state. The first diameter threshold can refer to the diameter value of the cutting wire when it is in a normal state.

[0053] Optionally, the second tension threshold and the second diameter threshold can be determined according to the specifications of the cutting wire. For example, the second tension threshold can be taken as a first specified percentage (e.g., 40%) of the breaking tensile force of the cutting wire (e.g., 45 N). The second diameter threshold can be taken as a second specified percentage (e.g., 95%) of the nominal diameter of the cutting wire (e.g., 120 μm).

[0054] When the tension value is greater than the first tension threshold and less than or equal to the second tension threshold, or when the diameter value is less than the first diameter threshold and greater than or equal to the second diameter threshold, a slight abnormality in the cutting line can be identified. When the tension value is greater than the second tension threshold and less than the third tension threshold, and the duration is less than the first duration; or when the diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration is less than the second duration, a brief deviation in the cutting line can be identified, and the operator is only notified with a prompt message, without intervening in the production process. The reason is that slight, brief deviations (such as instantaneous tension fluctuations) are usually system noise or process disturbances and will not immediately cause the line to break. Premature intervention may introduce unnecessary interference. For example, the first and second tension thresholds can correspond to a yellow warning zone, and the third tension threshold can correspond to a red danger zone. When the tension value is in this yellow zone, the system only records and prompts. Similarly, a similar treatment is applied to slight decreases or brief low values ​​in the diameter. Specifically, in the risk judgment process executed by the controller, the tension value F and the diameter value D are first read. Then, it is determined whether the tension value F and the diameter value D meet any of the above conditions. If the conditions are met, the disconnection risk level flag will be set to "first risk level", and the instruction to "output early warning information" will be executed in parallel. This early warning information can be a yellow flashing prompt displayed on the human-machine interface, accompanied by the recording of the current F and D data.

[0055] As can be seen, by adopting the above-mentioned precise threshold and duration combination judgment conditions in this embodiment, a large number of meaningless interference signals can be effectively filtered out, avoiding the system from overreacting to normal operating condition fluctuations, thereby further improving the accuracy and effectiveness of the early warning.

[0056] In some implementations, the specific implementation of the step "determining the wire breakage risk index corresponding to the cutting wire based on the tension value and diameter value" may include: If the tension value and diameter value meet at least one of the following conditions, the breakage risk level of the cutting wire is determined to be the second risk level: The tension value is greater than the second tension threshold and less than the third tension threshold, and the duration of maintenance is greater than or equal to the first duration; The diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration is greater than or equal to the second duration; Accordingly, the specific implementation of the step "determining the target control strategy corresponding to the disconnection risk index" may include: If the risk level of wire breakage is the second risk level, the second control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of wire breakage. The second control strategy includes controlling the cutting equipment to reduce the tension value of the cutting wire and / or reducing the wire speed.

[0057] Following the example above, a higher risk level can be preset based on the first risk level. In some implementations, a second risk level can be predefined. The conditions for determining a level as the second risk level include: the tension value is greater than a second tension threshold and less than a third tension threshold, and the duration is greater than or equal to a first duration; or the diameter value is less than a second diameter threshold and greater than a third diameter threshold, and the duration is greater than or equal to a second duration. That is, when the parameter remains on the edge of danger for too long, the risk is determined to be upgraded.

[0058] When the risk level is determined to be the second risk level, the corresponding control strategy is the second control strategy, which includes controlling the cutting equipment to reduce the tension value of the cutting wire and / or reduce the wire's travel speed. This allows for the identification of risk states that are continuously worsening but do not require immediate shutdown, and enables proactive but minor intervention. The reason is that when a parameter (such as tension) remains high without decreasing, or a parameter (such as diameter) remains low without recovering, it indicates that the system may be experiencing a persistent disturbance or that the steel wire itself has suffered progressive damage. In such cases, it is necessary to actively adjust process parameters to eliminate the risk. For example, the first duration can be set to 50 milliseconds. If the tension value remains high for 50 milliseconds after exceeding the second threshold, the controller determines that the risk has escalated. Therefore, after the conditions for determining the first risk level are not met (or as a parallel judgment), the controller enters the second risk level determination process. The time (t_T, t_D) during which the continuous abnormal tension or diameter is detected reaches or exceeds the set duration threshold (t1, t2), where t1 is the first duration and t2 is the second duration. If so, the wire breakage risk level flag is set to the second risk level. Then, the second control strategy is executed. For example, the controller sends an analog command to the tension servo system, which lowers the system's target tension setpoint from its current value at a preset rate until the risk disappears. Simultaneously, the controller can also slightly reduce the wire's running speed by controlling the wire drive motor.

[0059] As can be seen, in this embodiment, by adopting the above-mentioned scheme of actively adjusting risks based on duration, abnormal states can be automatically repaired at a relatively low cost before risks lead to accidents. This helps to solve the problem of how to effectively deal with medium-risk issues while ensuring production continuity, thereby synergistically enhancing the technical effect of the present invention in actively intervening in line breakage risks.

[0060] In some implementations, the specific implementation of the step "determining the wire breakage risk index corresponding to the cutting wire based on the tension value and diameter value" may include: If the tension value and diameter value meet at least one of the following conditions, the breakage risk level of the cutting wire is determined to be the third risk level: The tension value is greater than the third tension threshold; The diameter value is less than the third diameter threshold; Accordingly, the specific implementation methods for determining the target control strategy corresponding to the disconnection risk index may include: If the risk level of the line break is the third risk level, the third control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of the line break. The third control strategy includes controlling the cutting equipment to stop running.

[0061] Following the example above, to address the most extreme and urgent working conditions and ensure equipment and material safety, this embodiment also provides a third risk level determination and emergency response plan. As mentioned earlier, when the risk level exceeds the response capabilities of the first two levels, the most timely safety measures need to be taken. In some implementations, a third risk level can be predefined. The conditions for determining a third risk level include: the tension value is greater than the third tension threshold; or the diameter value is less than the third diameter threshold. That is, when the physical parameters directly cross the preset highest safety threshold, the highest level alarm is immediately triggered. When the risk level is determined to be the third risk level, the corresponding control strategy is the third control strategy, which includes controlling the cutting equipment to stop operating. This provides a final safety barrier for the system. The principle is that when the tension value exceeds the highest threshold determined by the material's ultimate strength and safety factor, or when the diameter value shrinks to a point where it can no longer safely bear the current tension, any fine-tuning is irreversible. Only by immediately cutting off the power source and stopping operation can the occurrence of a wire breakage accident be prevented to the greatest extent, thereby protecting valuable materials (such as silicon crystal rods) from more serious damage. For example, the controller monitors the F and D values ​​at all times. Once it detects that F is greater than F_max_3 (the third tension threshold) or D is less than D_min_3 (the third diameter threshold), it immediately sets the risk level flag to "third risk level" and skips all lower-level judgments. The controller outputs an emergency stop signal, which directly cuts off the power circuits of the cutting-related spindle motor, tension servo drive, and mortar pump, while simultaneously emitting a sharp audible and visual alarm on the human-machine interface and on-site. In addition, in order to trace the source after an emergency stop, the controller can also lock and store the F and D data for the last period of time before the stop.

[0062] As can be seen, by adopting the above-mentioned hard shutdown judgment and handling scheme for extreme working conditions in this embodiment, the last line of defense for system safety is constructed. This further helps to solve the problem of how to avoid catastrophic consequences when the risk cannot be eliminated by parameter adjustment, thereby synergistically strengthening the technical effect of the present invention in comprehensively and effectively preventing and controlling the risk of line breakage.

[0063] In some implementations, the method may further include: If a warning message is detected from the cutting equipment, the historical tension and diameter values ​​of the cutting line are obtained within a specified time period before and after the warning message is issued.

[0064] The second tension threshold and the second diameter threshold are updated based on historical tension values ​​and historical diameter values.

[0065] For example, since the system's thresholds (such as the second tension threshold and the second diameter threshold) are key decision-making criteria during the execution of the graded intervention strategy, a threshold self-learning mechanism can be introduced in some implementations. For example, the controller is also configured to: if a warning message is detected from the cutting equipment (e.g., the system has executed any warning or intervention action in the first, second, or third control strategy), acquire the historical tension and historical diameter values ​​of the cutting wire within a specified time period before and after the warning message occurs; and then update the second tension threshold and the second diameter threshold based on this historical data and related information. This allows the system to learn from each "event" (whether or not it ultimately leads to wire breakage) and continuously optimize its own safety boundaries. This is because changes in material hardness, batch characteristics of the steel wire, and even ambient temperature can affect the dynamic baseline of tension and diameter, and fixed thresholds are difficult to adapt to these changes. By analyzing the data characteristics before and after the alarm event, the system can discover whether the current threshold setting is too sensitive (leading to frequent false alarms) or too conservative (leading to missed alarms). Specifically, the implementation of this algorithm includes the following steps. When a warning rated as Level 1 risk is triggered, the controller automatically records the continuous data sequence of F(t) and D(t) within 10 seconds before and after the alarm trigger time. The controller also stores related data such as material information (e.g., material type, hardness grade) and process formula (e.g., feed rate, wire speed, mortar concentration) in the historical database. After each cutting task ends or a certain number of events are accumulated, the system initiates a self-learning program. This program performs correlation analysis between historical alarm event data and corresponding successful / non-breakage results. For example, if no breakage occurs after multiple alarm events, and the operator reports that the warnings are ineffective, the system will determine that the current threshold is too conservative and automatically increase the second tension threshold by a certain percentage (e.g., increase by 2%) or decrease the second diameter threshold by a certain percentage (e.g., decrease by 1%). Conversely, if a breakage accident has occurred, and the system reviews the tension and diameter data from the minutes before the accident and finds that the parameters were on the edge of danger for a long time without triggering a higher-level alarm, the system will determine that the threshold is not sensitive enough and automatically tighten the second threshold (e.g., decrease the second tension threshold by 3%).

[0066] As can be seen, in this embodiment, by adopting the above-mentioned scheme of dynamically optimizing the threshold based on historical event data, the system's security boundary can be adaptively adjusted as production data changes. This further helps to solve the problem of false alarms or missed alarms caused by fixed thresholds, thereby synergistically enhancing the accuracy and reliability of the early warning system of the present invention.

[0067] In some implementations, the tension detection unit and the diameter detection unit are positioned at the target location in the cutting equipment to simultaneously detect the tension and diameter at the same point on the cutting line.

[0068] Considering that the controller needs to make decisions based on both tension and diameter values ​​simultaneously, it is necessary to ensure that tension and diameter data can be effectively correlated for analysis to improve the accuracy of risk assessment. In this embodiment, the physical layout of the tension and diameter detection units has been improved. Specifically, the tension and diameter detection units are positioned at target locations within the cutting equipment to synchronously detect the tension and diameter at the same point on the cutting line. This solves the analytical bias problem caused by spatially asynchronous data. The principle is that if the locations for detecting tension and diameter are far apart, the physical state of the steel wire (such as tension and wear) changes along the wire direction, resulting in measurements of different points. This leads to deviations in subsequent correlation analysis and risk assessment. By closely arranging the two sensors, it is ensured that they measure the same local location where the physical state of the steel wire is highly coupled, thus maximizing the analytical value of the "tension-diameter" data pair. For example, the target location could be near the guide rollers at the inlet and outlet of the cutting chamber. See [link to relevant documentation] for details. Figure 3 Behind the steel wire contact area of ​​the wire guide wheel at the wire feeding port, a proprietary integrated bracket is used to fix a miniature roller tension sensor and a laser micrometer on the bracket. The distance between the two in the direction of steel wire travel is less than a specified distance, so that the tension value measured by the tension sensor and the steel wire diameter value measured by the laser micrometer at that instant physically correspond to almost the same cross section on the steel wire.

[0069] It is evident that by adopting the above-mentioned synchronous detection scheme, the relevance and quality of the input data can be significantly improved. This further helps to solve the technical problem of misjudgment caused by data asynchrony, thereby synergistically enhancing the accuracy of the control decision of this invention.

[0070] In some embodiments, the target location includes the area between the wire feeding port and the wire feeding guide wheel of the cutting chamber in the cutting device, and / or the area between the wire taking port and the wire taking guide wheel of the cutting chamber in the cutting device, wherein the wire feeding guide wheel is used to feed the cutting wire into the cutting chamber and the wire taking guide wheel is used to take the cutting wire out of the cutting chamber.

[0071] Following the example above, the tension detection unit and the diameter detection unit need to be positioned at target locations capable of detecting the same point on the steel wire. In some implementations, the target location may include the area between the wire feeding port and the wire feeding guide roller in the cutting chamber of the cutting equipment, and / or the area between the wire take-up port and the wire take-up guide roller in the cutting chamber. The wire feeding guide roller is responsible for feeding new or partially used steel wire into the cutting chamber for cutting, while the wire take-up guide roller is responsible for removing the steel wire that has completed its cutting stroke from the cutting chamber. Since the detection unit at the wire feeding port can monitor the initial state of the steel wire before it enters the cutting zone, for example, detecting inherent defects in the steel wire itself (such as uneven diameter), and the detection unit at the wire take-up port monitors the state of the steel wire after the entire cutting process, it best reflects the cumulative effect of cutting load and steel wire wear. Therefore, with both deployed, the system can provide a comparison. For example, if the wire feeding port diameter is normal but the wire take-up port diameter is significantly smaller, it is determined that the wear is severe; if the tension at the wire feeding port fluctuates greatly, the problem may lie in the upstream wire feeding mechanism. Specifically, as... Figure 3 As shown, the first set of detection units is installed behind the feed guide roller at the feed inlet, and the second set of detection units is installed in front of the take-up guide roller at the take-up inlet. Inside each detection unit, the tension sensor and diameter sensor are integrated into a compact module.

[0072] As can be seen, in this embodiment, by adopting the above-mentioned scheme of deploying detection units at the wire feeding port and the wire receiving port, the most representative data can be collected at the key nodes of the process flow, which helps to solve the problem of how to obtain the steel wire status data of the entire cutting process and key nodes, thereby synergistically strengthening the ability of the system of the present invention to comprehensively perceive the risk of wire breakage.

[0073] In some implementations, the step "detecting the tension value of the cutting wire by means of a tension detection unit" may include: The tension detection unit is controlled to detect the tension value of the cutting line based on a first frequency.

[0074] The step "Detecting the diameter value of the cutting line using the diameter detection unit" may include: The diameter detection unit controls the diameter value of the cutting line based on the second detection frequency.

[0075] The first frequency and the second detection frequency are both greater than or equal to 1 kHz.

[0076] Considering that the tension detection unit and diameter detection unit need to collect dynamic data, in this embodiment, the tension detection unit is configured to detect the tension value of the cutting wire based on a first frequency during the cutting process; the diameter detection unit is configured to detect the diameter value of the cutting wire based on a second detection frequency during the cutting process; and both the first and second detection frequencies are greater than or equal to 1 kHz. This ensures that the sensing system has a sufficiently high time resolution to accurately capture rapid events that may lead to wire breakage. The principle is that during high-speed cutting, the interaction between the steel wire and the material, the mechanical vibration of the guide wheel system, etc., will generate high-frequency tension fluctuations, and many tension peaks that lead to wire breakage last only a few milliseconds or even less. If the sampling frequency is too low, for example, only 100 Hz (i.e., sampling once every 10 milliseconds), these fatal transient signals may be completely missed. Increasing the sampling frequency to 1000 Hz or higher (i.e., sampling once every 1 millisecond or less) ensures that the system can detect these brief danger signals. Specifically, the tension sensor is a high-dynamic-response piezoelectric force sensor with a resonant frequency of tens of kilohertz, and the sampling rate of the matching acquisition circuit is set to 2000 Hz. Similarly, the scanning rate of the laser micrometer is also set to 2000 Hz to ensure that its data is synchronized with the tension sensor data in time. It is evident that by adopting the above-mentioned high-frequency synchronous acquisition scheme, the system is able to capture critical transient risk signals. This further helps to solve the problem of missing high-risk events due to insufficient sampling frequency, thereby synergistically enhancing the system's ability to provide early warning and precise intervention for wire breakage risks.

[0077] In other embodiments, the tension detection unit is configured to detect the tension value of the cutting line based on a first frequency during the process of the cutting equipment cutting the material; The diameter detection unit is configured to detect the diameter value of the cutting line based on a second detection frequency during the process of the cutting equipment cutting the material; Both the first and second detection frequencies are positively correlated with the wire speed of the cutting equipment.

[0078] For example, before starting the cutting equipment, a target wire speed can be set according to the process formula. The controller reads this set value and calculates the corresponding initial detection frequency. During the cutting process, if the real-time wire speed changes due to load fluctuations, the controller continuously monitors the actual speed value. When the speed change exceeds a predetermined threshold, it immediately instructs the tension detection unit and the diameter detection unit to synchronously adjust their sampling frequency to ensure that the two data streams are always collected with a time resolution that matches the current working conditions.

[0079] In this embodiment, the dynamic frequency adjustment mechanism enables the system to maintain sufficient early warning sensitivity during high-speed cutting, reduce resource consumption during low-speed or standby, and avoid false alarms or missed alarms caused by fixed frequencies that are too high or too low.

[0080] In summary, the cutting equipment provided in this embodiment, by setting up a tension detection unit and a diameter detection unit, directly detects the tension and diameter values ​​of the cutting wire in real time during operation. The controller then controls the cutting equipment based on these two physical parameters, enabling the cutting equipment to know the load status and strength changes of the steel wire in real time. This allows the equipment to adjust its operating status in a timely manner when parameters are abnormal, transforming the response to wire breakage risk from reactive post-event handling to proactive pre-event intervention. As a result, the wire breakage rate is effectively reduced, the stability and production efficiency of the cutting process are improved, and material scrap and equipment damage caused by wire breakage are avoided, thus improving the overall processing quality and efficiency.

[0081] As an example, the control method for cutting equipment can be specifically applied to, for example... Figure 4 The system architecture shown can include a perception layer, a decision layer, an execution layer, and a human-machine interface. The modules in these layers can work together to complete the anti-breakage control of the cutting line.

[0082] The sensing layer can include dual-dimensional high-precision sensing. Its core function is to achieve high-frequency, high-precision synchronous acquisition of the dynamic tension and local diameter of the steel wire, providing reliable data support for subsequent decision analysis. Specifically, it includes a tension detection unit and a diameter detection unit. The tension detection unit can use a high-dynamic-response miniature tension sensor, directly installed at a key location near the tangent point between the steel wire and the guide wheel (such as the steel wire contact area between the inlet and outlet guide wheels). The sensor's installation method must ensure minimal interference with the steel wire path to avoid affecting normal cutting accuracy. This tension sensor measures the dynamic tension of the steel wire in real time at a frequency of at least 1kHz, accurately capturing instantaneous tension spikes during cutting. The diameter detection unit can use a non-contact high-precision laser micrometer, deployed in the same or adjacent position as the tension sensor to ensure spatial synchronization of the acquired data. This laser micrometer scans the outer diameter of the steel wire passing through its measurement area at a frequency of at least 1kHz, accurately identifying local diameter reductions that are not visible to the naked eye due to wear or original defects (e.g., microscopic diameter changes from a standard 120μm to below 115μm).

[0083] The decision layer is used to implement intelligent threshold management and early warning logic. Specifically, the decision layer is responsible for receiving the raw sensor signals from the perception layer, processing the data, assessing the risk, and outputting control commands. For example, the decision layer may include a signal processing and controller, a dual-threshold comparison module, and an adaptive optimization algorithm module. The signal processing and controller receives the raw signals from the tension sensor and the diameter detection unit, filters, reduces noise, and calibrates the raw signals to eliminate environmental interference, obtaining clean and accurate real-time tension value F(t) and real-time diameter value D(t). The dual-threshold comparison module presets two core safety thresholds as the basic standard for judging the risk of wire breakage. As an example, the two core safety thresholds include a dynamic tension safety threshold F_max (as described in the second tension threshold above) and a diameter safety threshold D_min (as described in the second diameter threshold above).

[0084] It is understandable that the dynamic tension safety threshold F_max is not the ultimate breaking strength of the steel wire, but rather a warning value set based on historical safety process data, with sufficient safety margin to ensure that there is still enough room for intervention and adjustment when this threshold is reached. The diameter safety threshold D_min can be set based on the initial nominal diameter of the steel wire and the allowable safe wear amount to ensure that the basic load-bearing strength requirements are still met when the local diameter of the steel wire is reduced to this threshold.

[0085] The dual threshold comparison module can also be configured with an adaptive optimization algorithm. This algorithm can continuously learn the tension and diameter time series data before and after each alarm event (regardless of whether it ultimately leads to wire breakage). Combined with the material characteristics of this cutting (such as block hardness and material uniformity), process formula (line speed, feed speed, mortar concentration), and other related information, it dynamically optimizes the values ​​of F_max and D_min, so that the threshold setting is closer and closer to the "optimal safety boundary" of actual production. This effectively reduces false alarms (warnings triggered when there is no risk) and missed alarms (warnings not triggered when there is risk), and improves the accuracy of warnings.

[0086] The execution layer is used for tiered rapid response. It is responsible for receiving control commands from the decision-making layer and performing tiered intervention operations through corresponding execution mechanisms to ensure rapid risk elimination. Specifically, it includes execution mechanisms and tiered intervention strategies. Execution mechanisms typically refer to servo motors or hydraulic adjustment systems that control the main force of the steel wire cutting machine, as well as the central control unit of the multi-wire cutting equipment. Each execution mechanism must have high-speed response capabilities to ensure that control commands can be implemented quickly.

[0087] Specifically, the tiered intervention strategy can instruct the controller to output different control commands based on the risk level assessment results, achieving differentiated intervention while balancing risk control and production efficiency. For example, the risk level can include a Level 1 warning (low risk): when tension or diameter data continuously deviates from the normal value but does not exceed the safety threshold, or when a slight, brief exceedance of the threshold occurs, it is judged as low risk. The system issues a warning prompt on the human-machine interface, records relevant data, but does not interfere with the normal production process, reminding operators to pay attention to subsequent status changes.

[0088] In addition, the risk level can also include a Level 2 warning (medium risk): when the tension continuously exceeds F_max or the diameter continuously falls below D_min for a set duration without showing a recovery trend, it is judged as medium risk. The controller immediately reduces the main system tension setpoint slightly by a preset slope, or slightly reduces the wire speed, while continuously monitoring parameter changes and attempting to eliminate the risk through parameter adjustments.

[0089] In addition, the risk level can also include a three-level alarm (high risk): when the tension or diameter parameters are severely out of control (e.g., tension exceeds F_max by more than 15%, diameter is less than D_min by less than 5%), or when the parameters still do not return to normal after a level-two warning intervention, it is judged as high risk. The controller immediately triggers the emergency stop procedure, cuts off the cutting-related power unit, and simultaneously issues a sharp audible and visual alarm signal to remind the operator to arrive at the scene in time to avoid the fault from escalating.

[0090] As an example, in practical applications, taking the multi-wire cutting scenario of monocrystalline silicon square ingots as an example, the following hardware deployment process can be performed before executing this control method: Step 1: Install the first detection unit behind the guide wheel at the wire feeding port before the steel wire enters the cutting chamber. The steel wire is relatively clean at this location, making it easy to measure its initial state.

[0091] Step 2: Install a second set of detection units in front of the take-up guide wheel after the steel wire leaves the cutting chamber. At this point, the steel wire has undergone a complete cut, and its tension and diameter changes best reflect the cutting load and wear.

[0092] Step 3: Each detection unit contains a roller-type miniature tension sensor and a laser micrometer, both integrated on a compact bracket to ensure that the measurement points are close together.

[0093] Step 4: The sensor signal is connected to the high-speed signal processing and controller located in the electrical cabinet via a shielded cable (a high-performance industrial PLC or a dedicated controller can be used).

[0094] Step 5: Connect the controller output to the main tension servo drive of the wire saw and the overall control system of the equipment.

[0095] Then, the following software deployment and parameter setting process can be performed: Step 1: During system initialization, manually enter the initial thresholds according to the specifications of the steel wire used (e.g., nominal diameter 120μm, breaking tensile strength 45N): set the dynamic tension safety threshold F_max to 18N (approximately 40% of the breaking tensile strength), and the diameter safety threshold D_min to 114μm (95% of the nominal diameter).

[0096] Step 2: Enable adaptive optimization. During the initial run, the system will record the baseline fluctuations in tension and diameter throughout the entire cutting process.

[0097] Step 3: When the first alarm occurs, the system automatically saves the data for 10 seconds before and after the alarm. If the connection is not interrupted after the alarm and the operator confirms it as a valid warning, the system will appropriately tighten the threshold (e.g., lower F_max to 17.5N) when cutting the same type of crystal rod next time, making the warning more sensitive.

[0098] Following the example above, after both the hardware and software are deployed, the following can be executed: Figure 5 The control flow shown is as follows: During the cutting process, the take-up sensor synchronously detects the tension and diameter signals of the cutting wire in real time. It then compares these signals with corresponding thresholds to determine if the tension or diameter exceeds the limit.

[0099] If tension or diameter exceeds limits, a tiered intervention is implemented, including issuing alerts, adjusting the cutting equipment, and stopping the cutting equipment. If tension or diameter does not exceed limits, the tension and diameter signals of the cutting wire continue to be monitored synchronously.

[0100] Finally, the data generated during this intervention was recorded, and the aforementioned thresholds were adaptively optimized based on the recorded data.

[0101] As a more concrete example, the control process of the cutting equipment under different abnormal scenarios can be as follows: Scenario 1 (e.g., a scenario with abnormal tension): During the cutting process, the wire take-up sensor detects a sharp increase in wire tension due to unknown reasons (e.g., localized hard spots), for example, rising from approximately 16.5N to 19.2N within 5ms, exceeding the current F_max (18N). Simultaneously, the diameter reading stabilizes at 117.8μm, within a safe range.

[0102] The controller immediately starts timing. If the tension value remains above F_max for 50ms, the controller determines it as a "Level 2 warning" and instantly sends a command to the push force servo system to linearly reduce the system's target tension setpoint from 16.5N to 15.3N (a decrease of approximately 7.3%). The actual tension then falls back and gradually decreases, recovering to below 17.8N after approximately 200ms, thus exiting the warning zone.

[0103] The potential risk of a network outage was automatically mitigated, and the disconnection process was uninterrupted. The system recorded the event and marked it as "effective intervention."

[0104] Scenario 2 (e.g., abnormal diameter scenario): When cutting reaches another process segment, the laser micrometer at the take-up end detects an abnormal reduction in the local diameter of the steel wire. For example, data shows that within approximately 150ms, the steel wire diameter continuously decreases from the normal 118.2μm to 112.5μm, falling below the current safe diameter threshold D_min (114μm). Simultaneously, the tension reading remains within the normal range of 16.8N, and no tension-related warnings are triggered.

[0105] The controller compares the diameter data in real time and determines that D(t) = 112.5 μm is lower than D_min = 114 μm, and immediately starts the over-limit timing.

[0106] The diameter value further decreased to 111.8 μm within 80 ms, and the cumulative time it remained below D_min reached 100 ms, with no upward trend observed. The controller determined it to be a "Level 2 Warning (Medium Risk)".

[0107] The controller determined that the effective load-bearing cross-sectional area of ​​this section of the steel wire had decreased by approximately 13.2% (from the nominal 120μm to 111.8μm) due to excessive wear or original microscopic defects. Continuing to cut with the current process parameters would pose an extremely high risk of wire breakage, and this risk could not be completely eliminated by simply reducing the tension.

[0108] The controller immediately sends instructions to the main force servo drive and the main control system: within 200ms, reduce the system tension setting from 16.8N to 15.0N (a reduction of about 10.7%), and at the same time reduce the wire speed from 600m / min to 550m / min (a reduction of about 8.3%), so as to reduce the overall stress on the weak section during the subsequent cutting process.

[0109] After the load reduction operation was completed, the system continuously monitored the diameter data of the subsequent steel wire entering the cutting chamber. During the subsequent approximately 15m of steel wire travel, the diameter gradually increased to above 116.5μm and returned to the normal range. The locally small-diameter steel wire at risk passed safely through the cutting zone under the load reduction conditions without any breakage.

[0110] The system marks this event as "diameter abnormality - effective intervention" and saves complete dual-parameter time-series data and intervention records for 15 seconds before and after the event.

[0111] Scenario 3 (such as a scenario where two parameters simultaneously trigger a level 3 alarm): During another cutting process, the steel wire simultaneously exhibits an abnormal combination of a sharp increase in tension and a local reduction in diameter: the tension rapidly increases from 17.0N to 22.5N within 10ms (exceeding 25% of the current F_max=18N), while the diameter decreases from 117.5μm to 109.3μm (below 4.1% of the current D_min=114μm).

[0112] The controller detected a "Level 3 Alarm (High Risk)" and immediately triggered an emergency shutdown procedure, cutting off the cutting power unit and emitting an audible and visual alarm. Upon inspection, operators found significant surface scratches and localized wear defects in the affected section of steel wire. Had the system not stopped in time, this defective section of wire would have been highly likely to break under sustained high tension. Thanks to the timely intervention of the system's Level 3 alarm, this high-risk event only caused a brief process interruption. Inspection confirmed the crystal ingot was undamaged, effectively preventing a significant loss from scrapping the entire ingot.

[0113] Using the above example, the system can optimize the data such as the judgment threshold and judgment time involved in the cutting process for the above three scenarios as follows: (1) Regarding the tension over-limit event in scenario one, the algorithm analysis suggests that the tension margin is insufficient when cutting this segment. The F_max optimization value of similar crystal rods in this cutting stage is adjusted to 17.5N to make the early warning more sensitive under the same working conditions in the future.

[0114] (2) For the abnormal diameter event in scenario 2, the algorithm stores the diameter decay rate curve corresponding to this type of wear feature into the reference feature library. If a similar diameter decrease trend is detected in subsequent cutting, the system will start preventive load reduction in advance before D(t) approaches D_min, turning passive alarm into active prediction.

[0115] (3) For the high-risk event of dual parameter superposition in scenario three, the algorithm marks the tension-diameter joint over-limit mode as the "highest danger level" feature. Once a similar dual parameter synchronous abnormal trend is identified, the system will automatically shorten the delay judgment time of the secondary warning (e.g., from 100ms to 50ms) to achieve agile acceleration of risk response.

[0116] Through the above methods, this embodiment constructs a real-time sensing, intelligent decision-making, and rapid response anti-wire breakage immune system, realizing comprehensive monitoring and graded proactive intervention of abnormal wire tension and local diameter defects, significantly improving the reliability and intelligence level of wire cutting process.

[0117] As can be seen, the control method provided in this embodiment, by synchronously monitoring the two key parameters of dynamic tension and local diameter during the operation of the steel wire at high frequency, accurately triggers graded early warning and automatically adjusts the equipment operating parameters before the tension abnormally increases or the steel wire becomes locally thinner and reaches the dangerous critical point, thereby achieving early prevention and control of the risk of wire breakage, effectively preventing the occurrence of wire breakage accidents, reducing production losses, and improving the overall operating efficiency of the equipment.

[0118] An embodiment of the present invention also provides a cutting device. The cutting device includes a cutting wire, a tension detection unit, a diameter detection unit, and a controller. The tension detection unit is configured to detect the tension value of the cutting line during the cutting process of the material by the cutting equipment; The diameter detection unit is configured to detect the diameter of the cutting line during the cutting process of the material by the cutting equipment; The controller is configured as follows: Receive tension value and diameter value; Based on the tension value and diameter value, the breakage risk index corresponding to the cutting wire is determined. The breakage risk index is used to characterize the probability of the cutting wire breaking in the current state. The cutting equipment is controlled based on the wire breakage risk index.

[0119] Figure 6 The diagram shown is a block diagram of an electronic device 500 provided in an embodiment of the present invention.

[0120] Reference Figure 6 The electronic device 500 includes a processing component 510, which further includes one or more processors, and memory resources represented by memory 520 for storing instructions, such as application programs, that can be executed by the processing component 510. The application programs stored in memory 520 may include one or more modules, each corresponding to a set of instructions. Furthermore, the processing component 510 is configured to execute instructions to perform the aforementioned cutting device control method.

[0121] Electronic device 500 may also include a power supply component configured to perform power management of electronic device 500, a wired or wireless network interface configured to connect electronic device 500 to a network, and an input / output (I / O) interface. Electronic device 500 may operate on an operating system stored in memory 520, such as Windows Server™, Mac OSX™, Unix™, Linux™, FreeBSD™, or similar.

[0122] A non-transitory computer-readable storage medium, wherein when the instructions in the storage medium are executed by the processor of the aforementioned electronic device 500, the electronic device 500 is able to execute the aforementioned cutting device control method.

[0123] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0124] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0125] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0126] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0127] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0128] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program verification codes, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0129] Furthermore, it should be noted that the combination of the various technical features in this case is not limited to the combination methods described in the claims of this case or the combination methods described in the specific embodiments. All technical features described in this case can be freely combined or combined in any way, unless they contradict each other.

[0130] It should be noted that the above examples are merely specific embodiments of the present invention, and the present invention is obviously not limited to the above embodiments, with many similar variations. All modifications that can be directly derived or conceived by those skilled in the art from the content disclosed in this invention should fall within the protection scope of this invention.

[0131] It should be understood that the terms "first," "second," etc., mentioned in the embodiments of the present invention are merely for the purpose of more clearly describing the use of the technical solutions in the embodiments of the present invention, and are not intended to limit the scope of protection of the present invention.

[0132] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A control method for a cutting device, characterized in that, The cutting equipment includes a cutting wire, a tension detection unit, and a diameter detection unit; the method includes: During the process of cutting materials by the cutting equipment, the tension value of the cutting line is detected by the tension detection unit; The diameter value of the cutting line is detected by the diameter detection unit. Based on the tension value and the diameter value, the breakage risk index corresponding to the cutting wire is determined. The breakage risk index is used to characterize the probability of the cutting wire breaking in the current state. The cutting equipment is controlled according to the wire breakage risk index.

2. The control method according to claim 1, characterized in that, The step of controlling the cutting equipment based on the wire breakage risk index includes: Determine the target control strategy corresponding to the aforementioned disconnection risk index; The cutting equipment is controlled based on the target control strategy.

3. The control method according to claim 2, characterized in that, The wire breakage risk index includes a wire breakage risk level. Determining the wire breakage risk index corresponding to the cutting wire based on the tension value and the diameter value includes: If the tension value and the diameter value satisfy at least one of the following conditions, then the breakage risk level of the cutting wire is determined to be the first risk level: The tension value is greater than the first tension threshold and less than or equal to the second tension threshold; The tension value is greater than the second tension threshold and less than the third tension threshold, and the duration of maintenance is less than the first duration; The diameter value is less than the first diameter threshold and greater than or equal to the second diameter threshold; The diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration during which the diameter value is less than the second diameter threshold is less than the second duration; The determination of the target control strategy corresponding to the disconnection risk index includes: If the breakage risk level is the first risk level, the first control strategy among the preset multiple control strategies is used to determine the target control strategy corresponding to the breakage risk level. The first control strategy includes controlling the cutting device to output early warning information, which is used to indicate that there is a breakage risk in the cutting wire.

4. The control method according to claim 3, characterized in that, The step of determining the breakage risk index corresponding to the cutting wire based on the tension value and the diameter value includes: If the tension value and the diameter value satisfy at least one of the following conditions, then the breakage risk level of the cutting wire is determined to be the second risk level: The tension value is greater than the second tension threshold and less than the third tension threshold, and the duration of maintenance is greater than or equal to the first duration; The diameter value is less than the second diameter threshold and greater than the third diameter threshold, and the duration is greater than or equal to the second duration; The determination of the target control strategy corresponding to the disconnection risk index includes: If the risk level of the wire breakage is the second risk level, the second control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of the wire breakage. The second control strategy includes controlling the cutting equipment to reduce the tension value of the cutting wire and / or reduce the wire travel speed of the cutting wire.

5. The control method according to claim 4, characterized in that, The step of determining the breakage risk index corresponding to the cutting wire based on the tension value and the diameter value includes: If the tension value and the diameter value satisfy at least one of the following conditions, then the breakage risk level of the cutting wire is determined to be the third risk level: The tension value is greater than the third tension threshold; The diameter value is less than the third diameter threshold; The determination of the target control strategy corresponding to the disconnection risk index includes: If the risk level of the wire breakage is the third risk level, the third control strategy among the preset multiple control strategies will be used to determine the target control strategy corresponding to the risk level of the wire breakage. The third control strategy includes controlling the cutting equipment to stop operating.

6. The control method according to claim 3, characterized in that, The control method further includes: If the cutting device outputs a warning message, then the historical tension value and historical diameter value of the cutting line are obtained within a specified time period before and after the cutting device outputs the warning message; The second tension threshold and the second diameter threshold are updated based on the historical tension value and the historical diameter value.

7. The control method according to any one of claims 1 to 6, characterized in that, The tension detection unit and the diameter detection unit are positioned at the target location within the cutting equipment. Used to simultaneously detect the tension and diameter values ​​at the same point on the cutting line.

8. The control method according to claim 7, characterized in that, The target position includes the area between the wire feeding port and the wire feeding guide wheel of the cutting chamber in the cutting device, and / or the area between the wire taking-up port and the wire taking-up guide wheel of the cutting chamber in the cutting device. The wire feeding guide wheel is used to feed the cutting wire into the cutting chamber, and the wire taking-up guide wheel is used to feed the cutting wire out of the cutting chamber.

9. The control method according to any one of claims 1 to 6, characterized in that, The step of detecting the tension value of the cutting line through the tension detection unit includes: The tension detection unit is controlled to detect the tension value of the cutting line based on a first frequency; The step of detecting the diameter value of the cutting line by the diameter detection unit includes: The diameter detection unit is controlled to detect the diameter value of the cutting line based on a second detection frequency; Both the first frequency and the second detection frequency are greater than or equal to 1 kHz.

10. The control method according to any one of claims 2 to 6, characterized in that, The second tension threshold is 40% of the breaking tensile force of the cutting wire; The second diameter threshold is 95% of the nominal diameter of the cutting line.

11. A cutting device, characterized in that, The cutting equipment includes a cutting wire, a tension detection unit, a diameter detection unit, and a controller. The tension detection unit is configured to detect the tension value of the cutting line during the process of the cutting equipment cutting the material; The diameter detection unit is configured to detect the diameter value of the cutting line during the process of the cutting equipment cutting the material; The controller is configured as follows: Receive the tension value and the diameter value; Based on the tension value and the diameter value, the breakage risk index corresponding to the cutting wire is determined. The breakage risk index is used to characterize the probability of the cutting wire breaking in the current state. The cutting equipment is controlled according to the wire breakage risk index.

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