A slotting apparatus based on a bending electrothermal blade and a method of using the same

Abstract

The present application relates to pearl wool processing equipment technical field, specifically is a kind of slotting equipment based on bending electric heating blade and its using method.The present application relates to pearl wool processing equipment technical field, specifically is a kind of slotting equipment based on bending electric heating blade and its using method, including rack, conveying belt, bending electric heating blade, driving mechanism, lifting support mechanism and tool rest;Driving mechanism drives the conveying belt to convey pearl wool board, lifting support mechanism is used to adjust the height of tool rest and bending electric heating blade.Bending electric heating blade is sequentially formed first heating blade section, intermediate heating blade section and second heating blade section along the direction of current conduction, three series form single continuous conduction loop, and gap is left between adjacent blade tip portion and does not contact each other.Each heating blade section forms special-shaped hot cutting profile, can improve heating uniformity, reduce coking, wire drawing and strip cutting texture, improve groove consistency.

Description

Technical Field

[0001] This invention relates to the field of pearl cotton processing equipment technology, specifically a grooving device based on a bending electric heating blade and its usage method. Background Technology

[0002] EPE foam, also known as pearl cotton, is often processed into packaging liners that conform to the shape of the product being packaged due to its lightweight, flexibility, and good cushioning properties. For products with curved outer surfaces or sloping support surfaces, it is necessary to process irregularly shaped long grooves composed of two sloping sides and a central groove surface on thicker EPE sheets. Compared to ordinary straight cutting, this type of irregularly shaped long groove requires different cutting parts of the die to act synchronously on the EPE foam, and the degree of melting at each cutting part must be basically consistent. Otherwise, uneven cutting textures can easily form on the groove surface, affecting the slope of the groove and the continuity of the support surface.

[0003] Existing technologies have disclosed various devices for cutting pearl cotton or packaging liners using electric heating elements. For example, CN208681794U discloses a pearl cotton strip cutting device, which sets an electric heating wire on a C-shaped handheld frame and adjusts the voltage and current through a transformer to regulate the heat generated by the heating wire, while using a tensioning element to keep the heating wire straight. This solution can meet the requirement of straight cutting of pearl cotton strips, and its heat regulation mainly targets a continuous, basically straight electric heating wire. However, it does not address the conductivity relationship and heating consistency issues between multiple heating blades forming an irregular groove profile in different directions.

[0004] CN218659320U discloses a packaging liner hot-cutting machine, which drives a cutting blade to move via a longitudinal guide rail, a transverse guide rail, and a rotating assembly. A spiral heating wire is installed on the upper outer arc surface of the cutting blade to achieve hot-cutting of the packaging liner. This solution focuses on the position movement and directional rotation of the cutting blade and the clamping of the packaging liner. The heating wire is used as a heating element attached to the outer arc surface of the cutting blade. Based on the disclosed content, this solution does not provide a specific structure for bending a single heating blade into multiple actual cutting segments, and for ensuring that all segments are in the same continuous conductive path by limiting the connection order of each segment and the disconnection relationship between adjacent blade tips.

[0005] CN217943449U discloses an automated and efficient cutting device for EPE (Expanded Polyethylene) foam. This device uses an adjustable-gap side conveyor belt to clamp both sides of the EPE foam and employs limiting and pressing structures to reduce the foam's movement, popping out, and uneven cuts during conveying and cutting. This solution primarily improves cut quality by enhancing the conveying stability of the EPE foam and the compression near the cutting position. However, the cutting blade used does not further address the current distribution issue within the different heating segments of the irregularly shaped electrothermal blade.

[0006] As can be seen from the existing technology, current EPE foam cutting equipment typically improves cutting quality by adjusting the overall temperature of the heating wire, the position and movement of the cutting blade, or the clamping and conveying of the EPE foam. However, for long grooving dies that require a composite irregular groove surface to be formed by the first, middle, and second cutting sections, existing solutions still lack specific design for the conductive paths of each cutting section. According to the actual processing conditions of existing equipment, when an intermediate vertical blade is added between the two side cutting sections, if the intermediate vertical blade is not connected to a closed circuit, it cannot heat up sufficiently and mainly generates squeezing and dragging effects during the movement of the EPE foam, which can easily lead to insufficient cutting in the middle and stringing. If the intermediate vertical blade is connected to the circuit through a copper wire or directly connected through an additional blade, it is easy to form a conductive structure with both main and branch circuits. This causes the current passing through the cutting section before the shunt position to be greater than that of the branch cutting section, resulting in some cutting sections having excessively high temperatures and others having insufficient temperatures.

[0007] The aforementioned differences in current distribution directly affect the forming quality of the pearl cotton groove surface. Areas with higher-temperature cutting sections experience greater melting, leading to groove surface collapse, localized charring, or increased groove width. Conversely, areas with lower-temperature cutting sections are prone to insufficient melting, material stringing, and surface roughness. Because different cutting sections form different slopes or central groove surfaces, inconsistent melting degrees in different areas create strip-like cutting textures extending along the sheet material conveying direction, resulting in steps and unevenness between adjacent groove surfaces. This ultimately manifests as uneven curved surface slopes and poor groove depth consistency. Simply increasing the overall power supply voltage further exacerbates the overheating of the high-temperature cutting sections, while simply decreasing the power supply voltage makes it even more difficult for the low-temperature cutting sections to achieve effective melting. Therefore, it is difficult to eliminate this defect through overall temperature regulation. Summary of the Invention

[0008] The purpose of this invention is to provide a grooving device based on a bent electrothermal blade and its usage method, so as to solve the technical problems mentioned in the background art.

[0009] Based on the above ideas, the present invention provides the following technical solution: A grooving device based on a bent electrothermal blade, comprising: Includes frame, conveyor belt, bending electric heating blade, drive mechanism, lifting support mechanism and blade holder; The conveyor belt is mounted on the frame, and the drive mechanism is connected to the conveyor belt for driving the conveyor belt to transport the pearl cotton board to be slotted. The lifting support mechanism is disposed on both sides of the conveyor belt, and the cutter holder is disposed across the top of the conveyor belt. The two ends of the cutter holder are respectively connected to the corresponding lifting support mechanism to adjust the height of the cutter holder relative to the conveyor belt. The bending electric heating blade is mounted on the blade holder and located above the conveyor belt; The bent heating blade extends continuously along its own length and is bent to form an irregular structure. The bent heating blade sequentially forms a first heating blade segment, a middle heating blade segment, and a second heating blade segment along the current conduction direction. The first heating blade segment, the middle heating blade segment, and the second heating blade segment are connected in series between the two power supply terminals of the bent heating blade to form a single continuous conductive circuit. The bent electric heating blade has two adjacent blade tips with a gap between them and they do not contact each other to prevent the two blade tips from overlapping and forming a short circuit. The first heating blade segment, the intermediate heating blade segment, and the second heating blade segment together form an irregular hot-cutting profile that is adapted to the groove to be processed.

[0010] Preferably, the bent electric heating blade is an integral continuous blade, and the first heating blade section, the intermediate heating blade section and the second heating blade section are made of the same blade material and have the same cross-sectional dimensions.

[0011] Preferably, the effective conductive lengths of the first heating blade segment, the intermediate heating blade segment, and the second heating blade segment are the same or similar, so that the resistance and heat generation of the first heating blade segment, the intermediate heating blade segment, and the second heating blade segment tend to be consistent.

[0012] Preferably, both the first heating blade segment and the second heating blade segment include a vertical extension segment, a horizontal extension segment connected to the vertical extension segment, and an inclined extension segment connected to the horizontal extension segment, with the ends of the two inclined extension segments that are close to each other forming the blade tip.

[0013] Preferably, the gap between the two blade tips is configured to prevent the two blade tips from contacting each other and to reduce uncut strip marks formed between the two blade tips on the pearl cotton sheet.

[0014] Preferably, the lifting support mechanism includes lifting columns located on both sides of the conveyor belt, and the two ends of the blade holder are adjustablely connected to the two lifting columns to adjust the cutting depth of the bending electric heating blade relative to the conveyor belt.

[0015] Preferably, the conveyor belt is wound around the outside of the driving roller and the driven roller, and the drive mechanism includes a motor and a speed reduction transmission assembly, wherein the motor is connected to the driving roller through the speed reduction transmission assembly.

[0016] Preferably, adjustable limiting clamps are provided on both sides of the conveyor belt, and a conveying channel for the pearl cotton board is formed between the two limiting clamps to restrict the lateral movement of the pearl cotton board during the grooving process.

[0017] A method for using a grooving device based on a bent electric heating blade, characterized in that, by applying the aforementioned grooving device based on a bent electric heating blade, the method includes: S1. Select the appropriate bending electric heating blade according to the length, width and thickness of the pearl cotton board to be grooved and the shape of the groove to be processed; S2. Install the bending electric heating blade on the tool holder, and adjust the height of the tool holder relative to the conveyor belt through the lifting support mechanism so that the cutting depth of the bending electric heating blade matches the depth of the groove to be processed. S3. Connect the two power supply terminals of the bent electric heating blade to the heating power supply, so that the current flows through the first heating blade segment, the intermediate heating blade segment and the second heating blade segment in sequence, and the first heating blade segment, the intermediate heating blade segment and the second heating blade segment generate electric heat; S4. Start the drive mechanism to drive the conveyor belt and place the pearl cotton sheet on the conveyor belt; S5. The conveyor belt drives the pearl cotton sheet through the bending electric heating blade, so that the first heating blade section, the middle heating blade section and the second heating blade section together perform hot cutting on the pearl cotton sheet to form a groove corresponding to the irregular hot cutting contour of the bending electric heating blade. S6. Inspect the pearl cotton board after grooving, and adjust the heating temperature of the bending electric heating blade, the height of the blade holder and the running speed of the conveyor belt according to the depth of the groove, the position of the groove, the flatness of the groove surface, the condition of the filaments and the condition of the scorch marks.

[0018] The technical solution of the present invention may include the following beneficial effects: Compared with existing technologies, this invention, by sequentially arranging the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2 along the extension direction of the bent heating blade in the same continuous conductive circuit, and maintaining a non-contact gap between adjacent blade tips, avoids the intermediate blade segment not being connected to a closed circuit and thus not heating up, as well as short circuits, bypasses, and current shunting caused by direct overlap or additional wire connections between adjacent blade segments. Current can flow sequentially through each heating blade segment according to a predetermined path, ensuring that each blade segment involved in the groove forming receives effective heating. This reduces localized charring, over-melting, and groove width expansion caused by excessively high temperatures in some blade segments, as well as insufficient cutting, material dragging, and wire drawing caused by insufficient temperatures in some blade segments. It solves the specific problem of inconsistent heating states when blade segments in multiple directions are used to process irregularly shaped long grooves.

[0019] This invention employs continuous electrothermal blades bent according to the target groove contour, ensuring that each heating blade segment uses the same blade material and has the same or similar cross-sectional dimensions. By adjusting the dimensions of each straight segment, inclined segment, and bending transition segment, the effective conductive length of each heating blade segment is made the same or similar, thereby making the resistance and heat generation of each heating blade segment more consistent. The bending structure also shortens the continuous overhang length of the blade in a single direction, reducing the possibility of sagging, warping, and contour drift after the long blade is continuously heated, allowing the irregular hot-cut contour of the bent electrothermal blade to be stably replicated onto the pearl cotton board. The resulting groove has a continuous arc surface in the middle, and a uniform transition between the side slopes and the central arc surface, which can significantly reduce unintended strip-shaped cutting textures, local unevenness, and abrupt slope changes along the conveying direction, improving groove depth consistency, arc surface flatness, and continuous grooving quality.

[0020] In continuous processing, this invention can simultaneously acquire temperature differences, heating current and voltage, conveying speed, blade cutting depth, actual plate thickness, and groove surface detection results for each heating blade segment. It then determines thermal anomaly indicators reflecting heat input and heating uniformity, as well as groove geometry anomaly indicators reflecting the influence of groove depth, slope, and plate thickness. Based on the correlation between these two factors, it generates target heat input per unit length, target conveying speed, and target cutting depths at both ends of the blade holder. This method can distinguish the different impacts of localized heat imbalance, overall heat input mismatch, plate thickness variations, and blade holder position deviations on groove surface anomalies. It reduces parameter oscillations caused by repeated adjustments based solely on single coking, wire drawing, or groove depth results, ensuring coordinated heating, conveying, and cutting depth, further improving the processing stability of the equipment under continuous production conditions. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the grooving equipment of the present invention; Figure 2This is a schematic diagram of the structure of the bent electric heating blade of the present invention and its corresponding circuit. Figure 3 The diagram shows a comparison of different die-cutting structures and their corresponding circuits in the prior art. (a) is a die-cutting structure and its corresponding circuit with the middle die section not energized, (b) is a die-cutting structure and its corresponding circuit with copper wire connection, and (c) is a die-cutting structure and its corresponding circuit with blade connection. Figure 4 This is a schematic diagram of the actual structure of the bent electric heating blade of the present invention; Figure 5 This is a rendering of the pearl cotton groove surface formed after grooving using existing die-cutting technology; Figure 6 This is a rendering of the pearl cotton groove surface formed after grooving with the bent electric heating blade of the present invention. Figure 7 This is a flowchart illustrating the method of using the grooving equipment of the present invention.

[0022] In the diagram: 1. Frame; 2. Conveyor belt; 3. Bending electric heating blade; 4. Drive mechanism; 5. Lifting support mechanism. Detailed Implementation

[0023] Example 1 like Figures 1 to 7 As shown, this embodiment provides a grooving device based on a bent electric heating blade and its usage method, which is mainly used for continuous hot cutting and grooving of EPE pearl cotton boards, and is especially suitable for processing arc grooves, slope grooves and composite irregular grooves composed of multiple cutting areas.

[0024] like Figure 1 As shown, the grooving equipment includes a frame 1, a conveyor belt 2, a bending electric heating blade 3, a drive mechanism 4, a lifting support mechanism 5, and a blade holder for mounting the bending electric heating blade 3.

[0025] The frame 1 is used to support the conveyor belt 2, drive mechanism 4, lifting support mechanism 5, and tool holder. The lower part of the frame 1 is equipped with multiple support legs, and the bottom of each support leg is equipped with a flat mounting base, so that the grooving equipment can be placed stably on the working ground and reduce the shaking generated during conveying and grooving.

[0026] The conveyor belt 2 is located on the upper part of the frame 1, and is wound around the outside of the drive roller and the driven roller. The drive mechanism 4 is located at one end of the frame 1, and includes a motor and a reduction gear transmission assembly. The motor is connected to the drive roller through the reduction gear transmission assembly. After the motor starts, it drives the drive roller to rotate, and the drive roller drives the conveyor belt 2 to run continuously, thereby moving the pearl cotton sheets placed on the conveyor belt 2 in a predetermined direction.

[0027] Adjustable limiting clamps can also be installed on both sides of the conveyor belt 2. Before grooving, the distance between the two limiting clamps is adjusted according to the width of the pearl cotton board, so that the two limiting clamps are located on both sides of the pearl cotton board, in order to limit the lateral swing of the pearl cotton board during the conveying process and prevent the pearl cotton board from shifting its position relative to the bending electric heating blade 3.

[0028] Lifting support mechanisms 5 are respectively disposed on both sides of the conveyor belt 2, and the blade holder is horizontally disposed above the conveyor belt 2, with both ends of the blade holder connected to the corresponding lifting support mechanism 5. In this embodiment, the lifting support mechanism 5 includes a column, a connecting seat that moves up and down along the column, and a threaded adjustment component for locking the position of the connecting seat. By adjusting the two lifting support mechanisms 5, the height of the blade holder relative to the conveyor belt 2 can be changed, thereby adjusting the depth to which the bending electric heating blade 3 cuts into the pearl cotton board.

[0029] To ensure consistent cutting depth on both sides of the bending heating blade 3, the two lifting support mechanisms 5 can be adjusted separately to keep the blade holder horizontal. When a groove with varying tilt depth is required, the height of both ends of the blade holder can be adjusted according to the product drawings. After the blade holder is adjusted to the target position, it is locked using a threaded adjustment component to prevent it from shifting downwards during continuous production.

[0030] The bent heating blade 3 is installed at the lower part of the blade holder and spans across the conveyor belt 2 in a direction intersecting the conveying direction of the conveyor belt 2. Both ends of the bent heating blade 3 are connected to the blade holder via insulating fasteners and are respectively connected to the two power supply terminals of the heating power supply. The insulating fasteners are used to separate the bent heating blade 3 from the blade holder to prevent current from bypassing through the blade holder.

[0031] like Figure 2 As shown on the left, the bent electric heating blade 3 is formed by bending a continuous electric heating blade according to the target groove shape, and it sequentially forms a first heating blade segment R1, an intermediate heating blade segment R3, and a second heating blade segment R2 along its own length direction.

[0032] The first heating blade segment R1 and the second heating blade segment R2 respectively form the cutting contours on both sides of the target groove. The middle heating blade segment R3 forms a downward-curving irregular bending path in the middle of the bent electric heating blade 3, which is used to form the middle cutting contour of the target groove. The first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 together constitute a complete hot-cutting contour that is adapted to the cross-section of the target groove.

[0033] The bent heating blade 3 forms two adjacent blade tips after being bent in the middle, with a gap between them, and the two blade tips do not contact each other. It should be noted that the gap is the spatial interval formed between two adjacent parts of the bent heating blade 3, and does not sever the conductive path of the bent heating blade 3. The bent heating blade 3 remains continuous along its own length, and the current needs to flow along the complete path after bending from the first heating blade segment R1 through the middle heating blade segment R3, and then through the second heating blade segment R2.

[0034] The gap between the two blade tips prevents adjacent blade tips from directly overlapping. When the two blade tips are in direct contact, the current flows directly through the contact point, bypassing part of the bent blade segment. This results in insufficient heating of the bypassed segment and creates a short circuit at the contact point. By maintaining an appropriate blade tip gap, the current can be directed through the entire heated blade segment along a predetermined bending path.

[0035] The gap between the blade tips should not be too large to avoid leaving excessively wide uncut strips on the corresponding positions of the pearl cotton board; the gap should also not be too small to prevent the two blade tips from contacting each other when the bent heating blade 3 expands due to heat or vibrates. In actual production, a gap can be reserved according to the thermal expansion of the blades, and then the gap can be adjusted by trial cutting to keep the two blade tips separated at the working temperature, while minimizing strip marks on the grooved surface.

[0036] like Figure 2 As shown on the right, the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 are equivalent to resistors R1, R3, and R2, respectively, and are connected in series between the two power supply terminals of the bent heating blade 3. After the heating power is turned on, the same current flows through the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 in sequence, causing all three heating blade segments to generate heat.

[0037] In this embodiment, the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 are made of the same material and have the same or substantially the same width and thickness. By adjusting the dimensions of each straight segment, inclined segment, and bending transition segment, the effective conductive lengths of the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2, calculated along the blade centerline, are the same or similar. Because the three heating blade segments have the same or similar material, cross-sectional dimensions, and effective conductive lengths, their resistance values ​​and the heat generated per unit time tend to be consistent, thereby ensuring that each cutting area of ​​the bending electric heating blade 3 has a relatively uniform working temperature.

[0038] like Figure 3 As shown, Figure 3 The three types of die-cutting molds in this case are all existing die-cutting molds used before the improvements in this case.

[0039] Figure 3Scheme a includes R1, R2, and an intermediate blade R3. R1 and R2 are located on the main conductive path, while the intermediate blade R3 does not form a closed conductive path. When the equipment is powered on, current flows through R1 and R2, generating heat, while no current flows through the intermediate blade R3, thus failing to reach the normal hot-cutting temperature for the EPE foam board. When the EPE foam board passes through this die, R1 and R2 can melt-cut the corresponding areas, while the intermediate blade R3 mainly mechanically squeezes and pulls the EPE foam board, easily causing insufficient cutting of the middle material, stringing, and discontinuity in the groove surface.

[0040] Figure 3 Scheme b uses copper wire to connect the middle vertical blade R3 to another blade segment, so that R1, R2, and R3 are all in a closed circuit. In this circuit structure, R1 is located before the current shunt position, and the current flowing through R1 is the sum of the branch currents flowing through R2 and R3. After passing through R1, the current flows to R2 and R3 respectively. As a result, the heat generated by R1 is significantly greater than that of R2 and R3. The area corresponding to R1 is prone to over-melting or even charring, while the temperature of the areas corresponding to R2 and R3 is relatively insufficient, and problems such as the pearl cotton not being able to be cut or the cut surface being rough may still occur.

[0041] Figure 3 Scheme c uses blades instead of copper wires for connection. Although R1, R2, and R3 can all conduct electricity and generate heat, the circuit relationship still shows that R1 is connected to the branch section formed by R2 and R3. The current flowing through the three blade segments is inconsistent, so the problem of R1 generating more heat and R2 and R3 generating less heat still exists. Simply replacing the copper wire with blades cannot eliminate the uneven heat distribution caused by the branch circuit.

[0042] like Figure 4 As shown, Figure 4 This is the actual installation state of the bent heating blade 3 in this embodiment. The bent heating blade 3 is mounted on an insulating mounting plate, with its two ends positioned by wiring fasteners, and the middle bending area maintained in a predetermined shape by positioning elements. The bent heating blade 3 is pre-bent according to the contour of the groove to be processed, so that it can maintain the corresponding curvature and bending shape after being energized and heated.

[0043] Because the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 in this embodiment form a single series conductive path, the problem of the middle vertical blade not heating up or multiple blade segments shunting for heating in existing die-cutting molds is avoided. At the same time, bending the original long straight blade into multiple interconnected blade segments can shorten the continuous overhang length in a single direction, reducing sagging, warping, and contour deformation caused by the blade softening due to heat.

[0044] like Figure 5 As shown, Figure 5 To adopt Figure 3The image shows a pearl cotton sheet obtained after grooving using an existing die. Due to uneven heat generation in different sections of the existing die, the degree of melting and cutting varies significantly across different areas of the pearl cotton sheet. At higher-temperature sections, the pearl cotton melts more; at lower-temperature sections, the pearl cotton is insufficiently melted. The grooved surface exhibits multiple cutting lines and undulations extending along the conveying direction, with discontinuous transitions between adjacent cutting areas, uneven surface slope, and potential localized stringing or roughness.

[0045] The aforementioned cutting textures are not the desired structure of the target groove shape, but rather unexpected processing marks resulting from inconsistent temperatures at different cutting sections. For pearl cotton linings that require the use of curved groove surfaces to support packaged products, such uneven textures can cause uneven stress on the supporting surface, making it difficult to meet the product's requirements for groove surface flatness and curvature consistency.

[0046] like Figure 6 As shown, Figure 6 This is a pearl cotton board obtained after grooving using the bending electric heating blade 3 in this embodiment. Since the current in the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 is the same, and the heat generation of the three blade segments is made to be consistent through blade segment length matching, the degree of melting and cutting of the pearl cotton board in each cutting area is basically the same.

[0047] Figure 6 The central arc surface of the trough shown is continuous and smooth, and the transition between the side slopes and the central arc surface is uniform, without any abnormalities. Figure 5 The image shows multiple distinct cutting textures and local unevenness. The overall outline of the bending electric heating blade 3 can be replicated relatively completely onto the pearl cotton board, ensuring that the slope and depth of the grooved surface remain consistent, and reducing scorching caused by local overheating and stringing and dragging caused by local insufficient temperature.

[0048] The following is combined Figure 7 This document describes how to use the grooving equipment in this embodiment.

[0049] S1. Select the matching bending electric heating blade 3 according to the specifications of the pearl cotton board and the target groove shape.

[0050] Specifically, the length, width, and thickness of the EPE foam board are confirmed according to the production notification, and the width, depth, curvature, and slope shape of the groove to be processed are confirmed according to the product drawings. Then, a bending electric heating blade 3 with a corresponding hot cutting profile is selected. In this embodiment, an EPE foam board with a length of 400mm, a width of 400mm, and a thickness of 100mm can be used for processing, but the specific dimensions of the EPE foam board can be adjusted according to the structure of the packaged product.

[0051] S2. Install the bent electric heating blade 3 onto the blade holder and adjust the cutting depth of the blade.

[0052] The two ends of the bent heating blade 3 are mounted on the insulating fixing parts at the bottom of the blade holder, so that the bent heating blade 3 spans the conveyor belt 2. Then, the two lifting support mechanisms 5 are adjusted to change the height of the blade holder relative to the conveyor belt 2, so that the distance between the lowest cutting position of the bent heating blade 3 and the conveyor belt 2 is adapted to the thickness of the pearl cotton board and the target groove depth.

[0053] In this embodiment, the cutting depth of the bending electric heating blade 3 is adjusted according to the product drawings, and the adjustment tolerance of the cutting depth can be controlled within ±3mm. After adjustment, the lifting support mechanism 5 is locked to prevent the blade holder from moving during the grooving process.

[0054] S3. Turn on the heating power supply to energize each heating blade segment along the same circuit and raise its temperature to the working state.

[0055] Connect the two power supply terminals of the bent electric heating blade 3 to the heating control circuit to turn on the equipment power. The equipment can be connected to a 380V industrial power supply, and the operating temperature of the bent electric heating blade 3 is controlled by the heating control circuit. In this embodiment, the bent electric heating blade 3 is heated to approximately 220°C.

[0056] After power is applied, the current flows sequentially along the first heating blade section R1, the middle heating blade section R3, and the second heating blade section R2, causing all three heating blade sections to heat up simultaneously. Feeding is only carried out after the temperature of the bending heating blade 3 reaches a stable operating state to avoid mechanically pulling on the pearl cotton board before the blade temperature reaches the required level.

[0057] S4. Start the drive mechanism 4 to drive the conveyor belt 2 to stably transport the pearl cotton board.

[0058] Start the drive mechanism 4, where the motor drives the drive roller to rotate via the reduction gear assembly, causing the conveyor belt 2 to run continuously. In this embodiment, the conveying speed can be adjusted to equipment speed settings 5-7. Place the pearl cotton sheet on the conveyor belt 2 and adjust the limiting clamps on both sides of the conveyor belt 2 to ensure that the pearl cotton sheet moves smoothly in the predetermined direction without significant lateral sway.

[0059] S5. Use the bending electric heating blade 3 to continuously perform irregular hot cutting and grooving on the pearl cotton board.

[0060] As the conveyor belt 2 carries the EPE foam sheet past the bending electric heating blade 3, the first heating blade section R1, the middle heating blade section R3, and the second heating blade section R2 act on the corresponding areas of the EPE foam sheet. The heat generated by the blades causes the EPE foam in contact with the blades to partially melt and be cut. As the EPE foam sheet continues to move, a shaped groove that extends continuously along the conveying direction is formed on the surface of the sheet.

[0061] The first heating blade section R1, the middle heating blade section R3, and the second heating blade section R2 together determine the shape of the cross-section of the tank. The cutting depth of the bent electric heating blade 3 determines the depth of the tank. The running speed of the conveyor belt 2 and the working temperature of the bent electric heating blade 3 together affect the melting degree and surface flatness of the tank surface.

[0062] S6. Check the tank depth, tank position and tank surface quality, and adjust the relevant process parameters.

[0063] Before commencing continuous production, a test cut is performed using a piece of pearl cotton board. After the test cut, the depth of the groove, the relative position of the grooves, the slope of the curved surface, the flatness of the groove surface, and whether there are any streaks, scorch marks, or obvious cutting textures are checked.

[0064] When the groove depth is insufficient, appropriately reduce the height of the tool holder or decrease the conveying speed; when the groove depth is too large, appropriately raise the tool holder; when the groove surface shows wire drawing or incomplete cutting, appropriately increase the working temperature of the bending electric heating blade 3 or decrease the conveying speed; when the groove surface shows excessive melting or scorch marks, appropriately decrease the working temperature or increase the conveying speed.

[0065] After the parameters are adjusted, a trial cut is performed again until the depth, position, and surface quality of the groove meet the requirements of the product drawings. Then, continuous feeding and grooving production can begin.

[0066] Through the above structure and usage method, the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2 in the bending electric heating blade 3 are arranged along a single series conductive path, so that current flows through all three blade segments; by controlling the material, cross-sectional size, and effective conductive length of the three blade segments, the heat generation of each blade segment tends to be consistent, thereby reducing the unexpected striped texture, local unevenness, stringing, and charring phenomena on the grooved surface of the pearl cotton, and reducing the possibility of deformation of the long blade after being heated.

[0067] Example 2 This embodiment further improves the grooving quality inspection and process parameter adjustment process. By placing the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2 in the same continuous conductive circuit, and ensuring that the material, cross-sectional dimensions, and effective conductive length of each heating blade segment are the same or similar, the heating uniformity among the heating blade segments can be improved. However, during continuous grooving, the actual thickness, local density, and bubble state of the pearl cotton board may change. The bent electric heating blade 3 may also experience temperature differences due to molten material adhering to its surface, changes in local heat dissipation conditions, changes in the contact state of the wiring terminals, and continuous heat deformation. Simultaneously, the actual conveying speed of the conveyor belt 2, the positions of the left and right ends of the blade holder, and the actual cutting depth of the bent electric heating blade 3 may also fluctuate. Therefore, even if the bent electric heating blade 3 forms a single continuous conductive circuit in its structure, the pearl cotton groove surface may still simultaneously exhibit groove depth deviation, local charring, stringing, strip-like cutting textures, and uneven arc slope.

[0068] When the above anomalies occur simultaneously, adjusting the lifting support mechanism 5 solely based on the groove depth detection results may easily misjudge the relative decrease in groove depth caused by the increase in plate thickness as an increase in blade height; adjusting the heating power of the bending electric heating blade 3 solely based on the coking or drawing conditions may easily overlook the influence of conveying speed and cutting depth on the heat input per unit length. If there is a temperature difference between the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2, adjusting only based on the average temperature of the three blade segments may result in the average temperature being within the allowable range, but some blade segments being overheated or underheated. Therefore, in this embodiment, while keeping steps S1 to S5 of Embodiment 1 unchanged, the original step S6 is divided into steps S6.1 to S6.4, and step S7 is further set. Thus, process parameter optimization results are formed based on thermal state anomalies and groove geometry anomalies, and the process parameter optimization results are applied to the bending electric heating blade 3, the drive mechanism 4, and the lifting support mechanism 5 respectively.

[0069] This embodiment adds a data acquisition and control system, which includes a temperature acquisition module, an electrical parameter acquisition module, a conveying speed acquisition module, a cutting depth acquisition module, a plate thickness acquisition module, a groove surface detection module, an industrial controller, and an execution control module. The temperature acquisition module, electrical parameter acquisition module, conveying speed acquisition module, cutting depth acquisition module, plate thickness acquisition module, and groove surface detection module are each connected to the industrial controller. The industrial controller, through the execution control module, is connected to the heating control circuit of the bending electric heating blade 3, the drive mechanism 4, and the two lifting support mechanisms 5.

[0070] The temperature acquisition module includes three non-contact infrared temperature sensors positioned facing the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2, respectively. These sensors are used to acquire the temperatures of the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2. The temperature measurement range of the three infrared temperature sensors is 100–300℃, the temperature resolution is no greater than 0.5℃, and the sampling frequency is 20–50Hz. Optionally, when the installation space for the bending heating blade 3 is insufficient for arranging infrared temperature sensors, thermocouples can be installed near the fixed ends of the three heating blade segments. A calibration relationship between the measured temperature at the fixed end and the temperature of the corresponding effective cutting area is pre-established, and the industrial controller calculates the operating temperature of each heating blade segment based on this calibration relationship.

[0071] An electrical parameter acquisition module is installed in the heating control circuit of the bent electric heating blade 3 to collect heating voltage and heating current. The sampling resolution of the heating voltage is preferably no greater than 1V, the sampling resolution of the heating current is preferably no greater than 0.1A, and the sampling frequency is 50–100Hz. The industrial controller obtains the instantaneous heating power based on the heating voltage and heating current at the same sampling moment, and obtains the average heating power and the degree of heating power fluctuation within a predetermined calculation time window.

[0072] The conveyor speed acquisition module includes a rotary encoder connected to the drive mechanism 4 or the drive roller of the conveyor belt 2, used to acquire the real-time conveyor speed of the conveyor belt 2. The sampling frequency of the conveyor speed is 20-50Hz, and the detection resolution is preferably no greater than 0.5mm / s. The cutting depth acquisition module includes linear displacement sensors respectively set at the left and right ends of the tool holder. The two linear displacement sensors respectively acquire the height of the left and right ends of the tool holder relative to the conveyor belt 2. The actual cutting depth of the left and right ends of the bending electric heating blade 3 is determined by the industrial controller in combination with the actual thickness of the pearl cotton board. The detection resolution of the linear displacement sensors is preferably no greater than 0.1mm.

[0073] The sheet thickness acquisition module is located upstream of the bending electric heating blade 3 and is used to acquire the actual thickness of the pearl cotton sheet before it enters the grooving area. The sheet thickness acquisition module can use a laser displacement sensor or two distance sensors located on the upper and lower sides of the pearl cotton sheet, respectively. Its thickness detection resolution is 0.1-0.5 mm, and the sampling frequency is 10-20 Hz.

[0074] The groove surface detection module is located downstream of the bending electrothermal blade 3 and includes an industrial camera and a laser contour sensor. The industrial camera is used to acquire images of the groove surface after grooving and to identify the coking area, the drawing area, and the strip-shaped cutting texture extending along the conveying direction of the pearl cotton sheet in the groove surface. The laser contour sensor is used to acquire the cross-sectional contour of the groove body and to obtain the actual groove depth, the left slope angle, the right slope angle, and the continuity of the groove bottom arc surface based on the cross-sectional contour. The acquisition frequency of the industrial camera can be 20-30 frames / s, and the image resolution is not less than 1920×1080 pixels; the acquisition frequency of the laser contour sensor can be 100-500 contours / s, and the groove depth detection resolution is preferably not greater than 0.1mm.

[0075] The industrial controller can consist of an industrial computer and a programmable logic controller (PLC). The industrial computer is used to perform data time alignment, signal preprocessing, tank surface image processing, tank contour processing, calculation of thermal state anomaly indicators, calculation of tank geometry anomaly indicators, and calculation of process parameter optimization results. The PLC receives control data output from the industrial computer and sends execution commands to the heating control loop, drive mechanism 4, and lifting support mechanism 5, respectively. The heating control loop may include a silicon controlled rectifier (SCR) power regulator or a solid-state voltage regulator module. The motor of drive mechanism 4 can adjust the conveying speed of conveyor belt 2 via a frequency converter. The two lifting support mechanisms 5 can each be equipped with servo electric adjustment components to adjust the height of the left and right ends of the tool holder, respectively.

[0076] The usage method of this embodiment includes steps S1 to S7.

[0077] S1. Based on the specifications of the pearl cotton board and the target groove shape, select a bending electric heating blade 3 that matches the target groove shape. Specifically, determine the nominal length, width, and thickness of the pearl cotton board according to production requirements, and determine the groove depth, groove width, left and right slope angles, and groove bottom curvature of the target groove body according to the product drawings, and then select a bending electric heating blade 3 with a corresponding irregular hot cutting profile.

[0078] S2. Install the bent heating blade 3 onto the tool holder, and adjust the initial cutting depth of the bent heating blade 3 using the lifting support mechanism 5. The two power supply ends of the bent heating blade 3 are respectively installed on the tool holder through insulating fasteners. The first heating blade section R1, the middle heating blade section R3, and the second heating blade section R2 sequentially form the same continuous conductive circuit. By adjusting the lifting support mechanisms 5 at the left and right ends of the tool holder respectively, the initial cutting depth of the bent heating blade 3 is adapted to the target groove depth, and the left and right ends of the tool holder are kept at a predetermined height.

[0079] S3. Turn on the heating power supply of the bent electric heating blade 3, so that the first heating blade segment R1, the middle heating blade segment R3 and the second heating blade segment R2 are energized in sequence along the same continuous conductive circuit and heated to the working state.

[0080] S4. Start the drive mechanism 4, which drives the conveyor belt 2 to move and transport the pearl cotton sheet along the predetermined direction to the grooving position where the bending heating blade 3 is located. In this embodiment, the initial conveying speed of the conveyor belt 2 is set to 80 mm / s. The conveying speed acquisition module collects the actual conveying speed of the conveyor belt 2 in real time to reduce the impact of load changes, conveyor belt slippage, or fluctuations in the rotational speed of the drive mechanism 4 on the grooving quality.

[0081] S5. Conveyor belt 2 drives the pearl cotton sheet past the bending heating blade 3. The first heating blade section R1, the middle heating blade section R3, and the second heating blade section R2 jointly perform continuous irregular hot cutting on the pearl cotton sheet, forming a groove on the pearl cotton sheet that corresponds to the irregular hot cutting contour of the bending heating blade 3. During the hot cutting process, the temperature acquisition module, electrical parameter acquisition module, conveyor speed acquisition module, cutting depth acquisition module, and sheet thickness acquisition module continuously collect corresponding data. The groove surface detection module detects the groove surface that has passed through the bending heating blade 3.

[0082] S6.1 The industrial controller synchronously receives temperature data, heating current data, heating voltage data, conveying speed data, position data of the left and right ends of the blade holder, actual thickness data of the pearl cotton board, groove surface image data, and groove cross-sectional contour data of the first heating blade segment R1, the middle heating blade segment R3, and the second heating blade segment R2, and performs time alignment and preprocessing on the data of different sampling frequencies and different installation positions.

[0083] In this embodiment, a 2-second calculation time window is used, with a 1-second overlap between adjacent calculation time windows. For data on temperature, voltage, current, conveying speed, tool holder position, and plate thickness, resampling is first performed according to a unified time base of 20Hz, and then a five-point median filter is used to remove instantaneous spikes. When the deviation between a sampled value and the median within its calculation time window exceeds three times the absolute deviation of the median within that calculation time window, the sampled value is identified as an abnormal sampled value, and the median of adjacent valid sampled values ​​is used as the replacement.

[0084] When the number of consecutive missing sampling points of a signal within a calculation time window does not exceed 5, linear interpolation is performed using adjacent valid sampling points. When the missing proportion of a signal is greater than 10% but not greater than 20% of the total number of sampling points in the calculation time window, the corresponding feature value in the previous valid calculation time window is used, and the current calculation time window is marked as a low confidence time window. When the missing proportion of temperature data, heating current data, or tank cross-sectional contour data of the first heating blade segment R1, the middle heating blade segment R3, or the second heating blade segment R2 exceeds 20%, the industrial controller does not generate new parameter adjustment instructions, maintains the previous stable process parameters, and outputs the corresponding sensor check prompts.

[0085] Because the groove surface detection module is located downstream of the bending electric heating blade 3, there is a spatial delay in the groove surface detection results relative to the blade temperature, electrical parameters, conveying speed, and cutting depth data. The industrial controller pre-stores the installation distance between the bending electric heating blade 3 and the groove surface detection module, and determines the time required for the pearl cotton board to move from the grooving position to the groove surface detection position based on the average conveying speed of the conveyor belt 2 within the corresponding time period, and matches the groove surface detection results with its corresponding grooving time.

[0086] The images of the trough surface captured by the industrial camera are sequentially subjected to brightness normalization, background segmentation, and morphological denoising. The industrial controller determines the charring area based on the area of ​​continuous low-brightness regions in the trough surface, the filamentation area based on the edge regions that protrude from the main contour of the trough surface and are in the form of thin, filamentous lines, and the strip-shaped cutting texture based on the periodic changes in the grayscale gradient along the conveying direction. The cross-sectional contour captured by the laser contour sensor uses the upper surface of the ungrooved area of ​​the pearl cotton board as a height reference. After reference surface correction, the actual trough depth, left and right slope angles, and the continuity of the curved surface are determined.

[0087] After preprocessing, each calculation time window forms a set of state data, which includes at least the temperature dispersion among the three heating blade segments, the degree of heating power fluctuation, the proportion of the coking zone, the proportion of the wire drawing zone, the intensity of the strip cutting texture, the groove depth deviation, the slope angle deviation, and the plate thickness deviation.

[0088] S6.2 The industrial controller determines the thermal state anomaly index X based on the temperature dispersion among the three heating blade segments, the degree of heating power fluctuation, the proportion of the coking zone, the proportion of the wire drawing zone, and the intensity of the strip cutting texture. The thermal state anomaly index X is used to characterize the degree to which the current grooving anomaly is caused by excessively high or low heat input from the bending electric heating blade 3, fluctuations in heating power, or uneven heating among the three heating blade segments.

[0089] The industrial controller calculates the average temperature of the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2 within the current calculation time window. It then determines the root mean square dispersion of the blade segment temperature based on the deviation of the three average temperatures from their arithmetic mean temperature. The industrial controller also obtains the instantaneous heating power sequence based on the heating voltage and heating current within the current calculation time window, and determines the degree of heating power fluctuation based on the standard deviation and average heating power of the instantaneous heating power sequence.

[0090] The coking region ratio is the proportion of pixels in the coking region to the total number of pixels on the effective groove surface; the wire drawing region ratio is the proportion of pixels in the wire drawing region to the total number of pixels on the effective groove surface; the strip-cut texture intensity is the proportion of the texture gradient energy along the conveying direction of the groove surface to the pre-calibrated maximum allowable texture gradient energy. The thermal anomaly index X is calculated using the following formula: ; In the formula, X is the thermal state anomaly index; ΔT rms T is the root mean square discrete value among the average temperatures of the first heating blade segment R1, the intermediate heating blade segment R3, and the second heating blade segment R2, in °C. s The target operating temperature for bending the electric heating blade 3 is given in °C; σ P This represents the standard deviation of instantaneous heating power within the current calculation time window, in W. The average heating power within the current calculation time window, in W; ρ b The proportion of the coking zone; ρ w The proportion of the wire drawing area; ρ r For the intensity of the strip-cut texture, ρ b ρ w and ρ r The value range is 0 to 1.

[0091] Formula 1 simultaneously incorporates the heat source state of the bent electric heating blade 3 and the actual quality state of the groove surface after hot cutting. When there is a temperature difference between the first heating blade section R1, the intermediate heating blade section R3, and the second heating blade section R2, the root mean square dispersion of the blade section temperature increases; when the heating power output is unstable or the terminal contact state changes, the degree of heating power fluctuation increases; when the local temperature is too high, the local temperature is insufficient, or the heat distribution is uneven, the proportion of the coking area, the proportion of the wire drawing area, or the intensity of the strip cutting texture increases accordingly. This avoids misjudgments caused by judging the thermal state solely based on the average blade temperature.

[0092] Preferably, when X is less than 0.08, the thermal state of the bent electric heating blade 3 is determined to be within the allowable range; when X is not less than 0.08 and not greater than 0.18, a slight thermal state abnormality is determined; when X is greater than 0.18, a significant thermal state abnormality is determined. The threshold can be calibrated based on the density of the pearl cotton board, the material of the bent electric heating blade 3, and the quality of the target groove surface.

[0093] S6.3 The industrial controller determines the groove geometry anomaly index Y based on the temperature dispersion, heating power fluctuation, groove depth deviation, slope angle deviation, and sheet thickness deviation among the three heating blade sections. The groove geometry anomaly index Y is used to characterize the degree to which the current groove depth deviation and uneven arc slope are caused by the cutting depth of the bent electric heating blade 3, the height of the left and right ends of the blade holder, the actual thickness of the pearl cotton sheet, and the degree of sufficient local hot cutting.

[0094] The industrial controller determines the root mean square deviation of the actual trench depth relative to the target trench depth based on multiple continuous cross-sectional profiles. The left and right slope angles are obtained through linear fitting of the corresponding slope profiles. The slope angle deviation reflects both the difference between the left and right slope angles and the deviation of the actual slope angle relative to the target slope angle. The plate thickness deviation is the absolute deviation of the actual thickness detected by the plate thickness acquisition module relative to the nominal thickness.

[0095] The trough geometry anomaly index Y is calculated according to the following formula: ; In the formula, Y is the geometric anomaly index of the trough shape; e h h represents the root mean square deviation of the actual trench depth relative to the target trench depth, in mm. s The target trench depth is in mm; e θ θ represents the slope angle deviation, in degrees (°). s The target slope angle is expressed in degrees (°). b b represents the absolute deviation of the actual thickness of the pearl cotton board from the nominal thickness, in mm; s This refers to the nominal thickness of the pearl cotton board, in mm.

[0096] Both the thermal anomaly index X and the groove geometry anomaly index Y incorporate the root mean square dispersion of the blade segment temperature and the degree of heating power fluctuation, establishing a parameter correlation between the two indices. This is because insufficient groove depth or discontinuous slope can be caused by mismatched blade holder height, insufficient temperature of the intermediate heating blade segment R3, or inadequate melting and cutting of the pearl cotton sheet by the bent electric heating blade 3. By retaining the blade segment temperature dispersion and heating power fluctuation in the groove geometry anomaly index Y, the possibility of directly attributing insufficient hot cutting to a positional deviation of the lifting support mechanism 5 can be reduced.

[0097] Preferably, when Y is less than 0.08, the channel geometry is determined to be within the allowable range; when Y is not less than 0.08 and not greater than 0.16, a slight channel geometry anomaly is determined to exist; when Y is greater than 0.16, an obvious channel geometry anomaly is determined to exist.

[0098] S6.4 The industrial controller determines the set of optimized process parameters based on the thermal anomaly index X and the groove geometry anomaly index Y. The set of optimized process parameters includes the target heat input per unit length, the target conveying speed, the target cutting depth at the left end of the tool holder, and the target cutting depth at the right end of the tool holder, which are used to control the heating state of the bending electric heating blade 3, the operating state of the drive mechanism 4, and the positions of the two lifting support mechanisms 5, respectively.

[0099] The industrial controller determines the heat adjustment direction indicator 's' based on the relationship between the average temperature of the three heating blade sections and the target operating temperature, as well as the relationship between the proportion of the coking zone and the proportion of the drawing zone. T When the average temperature of the three heating blade sections is higher than the target operating temperature, and the proportion of the coking zone is greater than the proportion of the drawing zone, s T Adding +1 indicates that the current heat input per unit length is too high; when the average temperature of the three heating blade sections is lower than the target operating temperature, and the proportion of the drawing area is greater than the proportion of the coking area, s T A value of -1 indicates that the current heat input per unit length is low; when coking and drawing are concentrated in different blade sections, and the average temperature of the three heating blade sections is within the allowable range of the target operating temperature, s T If the value is set to 0, the overall heat input will not be increased or adjusted, and a prompt will be output indicating local adhesion, local heat dissipation, or local deformation of the bent electric heating blade 3.

[0100] The industrial controller determines the groove depth adjustment direction indicator s based on the relationship between the average actual groove depth and the target groove depth. h When the average actual trench depth is greater than the target trench depth, s h Add 1 to reduce the cutting depth; when the average actual trench depth is less than the target trench depth, s h Set the value to -1 to increase the depth of cut.

[0101] The industrial controller determines the left and right leveling direction indicators (s) based on the actual tank depth and slope angle on both sides of the tank. θ When the actual cutting depth of the corresponding area on the left end of the tool holder is greater than that of the corresponding area on the right end of the tool holder, s θ Take +1; when the actual cutting depth of the corresponding area on the right end of the tool holder is greater than that of the corresponding area on the left end of the tool holder, s θ Set to -1; when the difference between the left and right sides is within the allowable range, s θ Take 0.

[0102] The set of optimized process parameters is determined according to the following formula: ; In the formula, This is a set of optimization results for process parameters; The target unit length heat input is expressed in J / mm. The target conveying speed is expressed in mm / s. The depth of cut into the target at the left end of the tool holder, in mm; q0 is the target cutting depth at the right end of the tool holder, in mm; v0 is the current heat input per unit length, which is determined by the average heating power and average conveying speed within the current calculation time window; h0 is the current conveying speed, in mm / s; α is the overall heat input correction coefficient, ranging from 0.20 to 0.40; λ is the coupling correction coefficient for thermal anomalies and groove geometry anomalies, ranging from 0.10 to 0.20; γ is the conveying speed correction coefficient, ranging from 0.10 to 0.30; β is the average cutting depth correction coefficient, ranging from 0.08 to 0.18; κ is the tool holder left and right leveling correction coefficient, ranging from 0.03 to 0.08.

[0103] The XY term in Formula 3 represents the coupling degree when thermal anomalies and groove geometry anomalies coexist. When both X and Y increase, it indicates that the groove depth deviation or slope anomaly may be related to insufficient hot cutting or excessive melting cutting. The industrial controller implements corresponding enhancement corrections to the heat input per unit length. When Y increases while X remains within the allowable range, it indicates that the current anomaly is mainly related to the plate thickness, the height of the tool holder, or the left and right leveling status. The industrial controller mainly adjusts the cutting depth at both ends of the tool holder to avoid excessive adjustment to the heating status of the bending electric heating blade 3 and the conveying speed of the conveyor belt 2.

[0104] The target heat input per unit length is converted into the target heating power of the bending electric heating blade 3 by the industrial controller. The execution control module sends corresponding control commands to the heating control loop according to the target heating power. The target conveying speed is sent to the frequency converter of the drive mechanism 4. The target cutting depth at the left end of the tool holder and the target cutting depth at the right end of the tool holder are respectively sent to the servo electric adjustment components of the two lifting support mechanisms 5, thereby simultaneously correcting the average groove depth and the difference between the left and right slopes.

[0105] To avoid sudden changes in process parameters caused by fluctuations in a single test, within each adjustment cycle, the variation of the target unit length heat input relative to the current unit length heat input shall not exceed ±8%, the variation of the target conveyor speed relative to the current conveyor speed shall not exceed ±5%, and the variation of the single cutting depth at the left or right end of the tool holder shall not exceed ±1.5mm. When the variation calculated by Formula 3 exceeds the corresponding limit range, the industrial controller decomposes the variation into multiple adjustment cycles and executes them sequentially.

Claims

1. A grooving device based on a bent electrothermal blade, characterized in that, include: It includes a frame (1), a conveyor belt (2), a bending electric heating blade (3), a drive mechanism (4), a lifting support mechanism (5), and a blade holder; The conveyor belt (2) is mounted on the frame (1), and the drive mechanism (4) is connected to the conveyor belt (2) for driving the conveyor belt (2) to transport the pearl cotton board to be slotted. The lifting support mechanism (5) is disposed on both sides of the conveyor belt (2), and the blade holder is disposed across the top of the conveyor belt (2). The two ends of the blade holder are respectively connected to the corresponding lifting support mechanism (5) to adjust the height of the blade holder relative to the conveyor belt (2). The bent electric heating blade (3) is mounted on the blade holder and located above the conveyor belt (2); The bent electric heating blade (3) extends continuously along its own length direction and is bent to form an irregular structure. The bent electric heating blade (3) forms a first heating blade segment, an intermediate heating blade segment and a second heating blade segment in sequence along the current conduction direction. The first heating blade segment, the intermediate heating blade segment and the second heating blade segment are connected in series between the two power supply terminals of the bent electric heating blade (3) to form a single continuous conductive circuit. The bent electric heating blade (3) has two adjacent blade tips with a gap between them and they do not contact each other to prevent the two blade tips from overlapping and forming a short circuit. The first heating blade segment, the intermediate heating blade segment, and the second heating blade segment together form an irregular hot-cutting profile that is adapted to the groove to be processed.

2. The grooving device based on a bent electrothermal blade according to claim 1, characterized in that, The bent electric heating blade (3) is an integral continuous blade. The first heating blade section, the intermediate heating blade section and the second heating blade section are made of the same blade material and have the same cross-sectional dimensions.

3. A grooving device based on a bent electrothermal blade according to claim 2, characterized in that, The effective conductive lengths of the first heating blade segment, the intermediate heating blade segment, and the second heating blade segment are the same or similar, so that the resistance and heat generation of the first heating blade segment, the intermediate heating blade segment, and the second heating blade segment tend to be consistent.

4. A grooving device based on a bent electrothermal blade according to claim 3, characterized in that, Both the first heating blade segment and the second heating blade segment include a vertical extension segment, a horizontal extension segment connected to the vertical extension segment, and an inclined extension segment connected to the horizontal extension segment. The ends of the two inclined extension segments that are close to each other respectively form the blade tip.

5. A grooving device based on a bent electrothermal blade according to claim 4, characterized in that, The gap between the two blade tips is configured to prevent the two blade tips from contacting each other and to reduce the uncut strip marks formed between the two blade tips on the pearl cotton sheet.

6. A grooving device based on a bent electrothermal blade according to claim 5, characterized in that, The lifting support mechanism (5) includes lifting columns located on both sides of the conveyor belt (2). The two ends of the blade holder are tunably connected to the two lifting columns to adjust the cutting depth of the bending electric heating blade (3) relative to the conveyor belt (2).

7. A grooving device based on a bent electrothermal blade according to claim 6, characterized in that, The conveyor belt (2) is wound around the outside of the drive roller and the driven roller. The drive mechanism (4) includes a motor and a speed reduction transmission assembly. The motor is connected to the drive roller through the speed reduction transmission assembly.

8. A grooving device based on a bent electrothermal blade according to claim 7, characterized in that, The conveyor belt (2) is provided with adjustable limiting clamps on both sides, and a conveying channel for the pearl cotton board is formed between the two limiting clamps to restrict the lateral movement of the pearl cotton board during the grooving process.

9. A method of using a grooving device based on a bent electrothermal blade, characterized in that, The grooving apparatus based on a bent electrothermal blade according to any one of claims 1 to 8, the method comprising: S1. Select the corresponding bending electric heating blade (3) according to the length, width and thickness of the pearl cotton board to be grooved and the shape of the groove to be processed. S2. Install the bent electric heating blade (3) on the tool holder, and adjust the height of the tool holder relative to the conveyor belt (2) through the lifting support mechanism (5) so that the cutting depth of the bent electric heating blade (3) matches the depth of the groove to be processed. S3. Connect the two power supply terminals of the bent electric heating blade (3) to the heating power supply so that the current flows through the first heating blade segment, the middle heating blade segment and the second heating blade segment in sequence, and the first heating blade segment, the middle heating blade segment and the second heating blade segment generate electric heat. S4. Start the drive mechanism (4), drive the conveyor belt (2) to run, and place the pearl cotton board on the conveyor belt (2); S5. The conveyor belt (2) drives the pearl cotton board through the bending electric heating blade (3), so that the first heating blade section, the middle heating blade section and the second heating blade section together perform hot cutting on the pearl cotton board to form a groove corresponding to the irregular hot cutting contour of the bending electric heating blade (3). S6. Inspect the pearl cotton board after grooving, and adjust the heating temperature of the bending electric heating blade (3), the height of the blade holder and the running speed of the conveyor belt (2) according to the depth of the groove, the position of the groove, the flatness of the groove surface, the condition of the filaments and the condition of the scorch marks.

Images