An aerated concrete block cutting device

Abstract

The application belongs to the technical field of building material processing equipment, and particularly relates to an aerated concrete block cutting device, which comprises a rack, a conveying roller frame one for aerated concrete block feeding, a conveying roller frame two for aerated concrete block discharging, and a cutting part for aerated concrete block cutting arranged between the conveying roller frame one and the conveying roller frame two; a profile detection part is installed on one side of the rack facing the conveying roller frame two, the profile detection part is used for collecting profile data of the aerated concrete block after cutting, uploading the profile data to a control box, comparing the profile data with preset profile data, and calculating a profile deviation value; and the control box drives a tension adjusting part to adjust the tension of the cutting steel wire according to the profile deviation value. Through the cooperation of the pushing unit, the tension detection part, the profile detection part and the tension adjusting part, the dynamic stability of the cutting steel wire tension and the closed-loop regulation and control of the blank pushing speed are realized, and the cutting precision and the discharging efficiency of continuous production are improved by the cooperation of the conveying roller frame.

Description

Technical Field

[0001] This invention belongs to the technical field of building material processing equipment, and specifically relates to an aerated concrete block cutting device. Background Technology

[0002] Autoclaved aerated concrete (AAC) blocks are a type of lightweight, porous building material with good thermal insulation and fire resistance, widely used in building wall infill and enclosure structures. The production process of AAC blocks involves cutting large-volume blanks, prepared through batching, mixing, pouring, and curing, into blocks that meet specific specifications.

[0003] Problems with existing technology: 1. Currently, most existing cutting devices fix aerated concrete blocks on a platform and then control the cutting wire to move towards the aerated concrete blocks to achieve cutting. However, this cutting method is prone to vibration during the cutting process, which makes the cut surface very prone to quality defects such as burrs and chipped corners.

[0004] 2. Traditional equipment lacks a real-time feedback mechanism for the outline of the finished product after cutting. Operators often only discover deviations after the entire batch of products is completed, resulting in waste of raw materials and increased rework costs.

[0005] 3. The existing cutting methods usually use fixed platforms, which results in low material feeding and unloading efficiency for block cutting, making it difficult to meet the cycle time requirements of continuous production lines. Summary of the Invention

[0006] The purpose of this invention is to provide an aerated concrete block cutting device that achieves dynamic stability of the cutting wire tension and closed-loop control of the billet pushing speed through the coordinated operation of the pushing unit, tension detection unit, contour detection unit and tension adjustment unit, and improves the cutting accuracy and output efficiency of continuous production by cooperating with the conveyor roller frame.

[0007] The specific technical solution adopted by this invention is as follows: An aerated concrete block cutting device includes a frame, a first conveyor roller frame for feeding aerated concrete blocks, and a second conveyor roller frame for unloading aerated concrete blocks. A cutting section for cutting aerated concrete blocks is also provided between the first conveyor roller frame and the second conveyor roller frame. A contour detection unit is installed on the side of the frame facing the second conveyor roller frame. The contour detection unit is used to collect the contour data of the aerated concrete blocks after cutting, and upload the contour data to the control box to compare with the preset contour data and calculate the contour deviation value. The control box drives the tension adjustment unit to adjust the tension of the cutting wire according to the contour deviation value, and drives the drive unit to adjust the pushing speed of the pushing unit through the control box.

[0008] A drive unit is fixedly mounted on one side of the frame via a mounting bracket. The drive unit drives the pusher unit to reciprocate through the transmission unit, so that the pusher unit pushes the aerated concrete block through the cutting wire. The drive unit includes a drive motor fixedly installed on one side of the mounting bracket. The drive motor drives the first swing arm to rotate through the transmission box, causing the first swing arm to swing one end of the first pull rod, and then drives the swing frame to swing through the other end of the first pull rod.

[0009] The swing frame is rotatably hinged to the inside of the machine frame, and one side of the swing frame is hinged to the pusher part through the second pull rod, so that the second pull rod pulls the pusher part to slide linearly inside the machine frame; The material pushing part drives the material pushing plate to slide synchronously in a straight line through the moving frame, and pushes the aerated concrete block toward the cutting part in a straight line through the material pushing plate.

[0010] A tension adjustment part is fixedly installed on one side of the frame. The tension adjustment part is used to drive the upper mounting part of the cutting part to rotate, so that the upper mounting part drives the upper end of the cutting wire to move in a fan shape, which is used to adjust the tension of the cutting wire. The other end of the cutting wire is fixedly installed to the frame through the lower mounting part. The frame is also equipped with a tension detection unit. The cutting wire abuts against the surface of the tension detection unit, and the tension of the cutting wire is acquired in real time through the tension detection unit and the tension data is transmitted to the control box.

[0011] The tension adjustment unit includes a fixed frame that is fixedly installed on one side of the frame. A cylinder hinged inside the fixed frame is used to push the second swing arm to move in a fan shape, so that the second swing arm drives the rotating shaft and the upper mounting part to move synchronously. The upper mounting parts are evenly distributed in multiple ways along the axis of the rotating shaft, and the side limiting brackets with external threads on the rotating shaft are used to abut against the upper mounting parts at both ends to limit and fix the ends of the multiple upper mounting parts.

[0012] The upper mounting part includes a sleeve that is slidably mounted along the axis of rotation. Connecting discs are installed at both ends of the sleeve. A screw and an adjusting sleeve are provided between the two sets of sleeves. The adjusting sleeve is used to drive the screw to rotate inside the fixing nut, so that the two sets of sleeves move towards each other. A connecting plate is fixedly connected to the surface of the sleeve. An upper fixed seat is rotatably hinged to one side of the connecting plate via a hinge shaft. A limiting groove is provided inside the connecting plate, allowing the upper fixed seat to slide along the limiting groove and be fixed by a locking bolt. This is used for fine adjustment of the tension between the upper fixed seat and the end of the cutting wire.

[0013] The bottom of the cutting wire is fixedly installed with the lower fixing seat, the lower fixing seat is slidably installed with the mounting plate through the through groove, and the side of the lower fixing seat is locked with the mounting plate through the fixing plate; The lower fixing seat, the upper mounting part, and the cutting wire are provided in multiple sets, and the multiple sets of the lower fixing seat and the upper mounting part are used to drive the multiple sets of cutting wires to adjust the spacing.

[0014] A lower mounting base and an upper mounting base are fixedly installed on one side of the frame. An upper laser contour scanner and a lower laser contour scanner are respectively installed inside the lower mounting base and the upper mounting base. The upper laser contour scanner and the lower laser contour scanner are set to correspond to the cutting wire. A contour detection path is provided between the upper laser contour scanner and the lower laser contour scanner, so that when the cut aerated concrete block passes through the contour detection path, the contour data of the aerated concrete block is collected by the upper laser contour scanner and the lower laser contour scanner.

[0015] A method for cutting aerated concrete blocks includes the following steps: Step S1: Set the initial pushing speed of the pushing unit and the initial target tension of the cutting wire; Step S2: The pushing unit pushes the aerated concrete block blank through the cutting wire of the cutting part in the transverse direction at the current pushing speed, and the cutting wire cuts the blank; Step S3: After the block is cut, it reaches the scanning area of ​​the contour detection unit. The upper and lower contours of the block are scanned by the upper laser contour scanner and the lower laser contour scanner to obtain the actual contour data of the block after cutting. Step S4: The control box compares the actual contour data obtained in step S3 with the preset standard contour data and calculates the contour deviation value; Step S5: Compare the contour deviation value calculated in step S4 with the preset quality threshold of the control box: If the contour deviation value is less than or equal to a preset quality threshold, the current process parameters remain unchanged; if the contour deviation value is greater than the preset quality threshold, at least one of the following adjustment operations is performed: When the surface flatness deviation exceeds the first preset threshold, the feeding speed is reduced according to the first adjustment step. When the kerf width deviation exceeds the second preset threshold, the tension setting is increased according to the second adjustment step. Step S6: Return to step S2 and cut the next blank using the adjusted process parameters.

[0016] In step S1, the initial feeding speed and the initial target tension are set as follows: Before cutting, the blank is pre-tested to obtain the hardness value of the blank. Based on the hardness value of the blank, the corresponding initial feeding speed and initial target tension are queried from the preset parameter matching table. The pre-detection method is as follows: insert the detection rod into the blank, detect the penetration resistance of the detection rod through a pressure sensor, and determine the hardness value of the blank based on the penetration resistance.

[0017] The technical effects achieved by this invention are as follows: This invention features a drive unit mounted on one side of the frame via a mounting bracket. Activation of the drive unit activates a transmission unit, which in turn drives a pushing unit in reciprocating motion. This reciprocating motion of the pushing unit pushes the blank located on the upper part of the conveyor roller frame towards the cutting unit. Since the cutting unit is fixedly mounted, compared to the moving cutting structure, it eliminates the need for a complex lifting drive system and frame vibration damping device. Simultaneously, the blank moves smoothly and uniformly under the push of the pushing unit, avoiding the impact of vibration from large moving parts on cutting accuracy. This results in higher flatness and dimensional consistency of the cut surface. Furthermore, the continuous movement of the blank allows the blocks to naturally flow to the downstream station after cutting, facilitating inspection downstream of the cutting mechanism and achieving seamless "cut and inspect immediately" integration. This provides an ideal hardware foundation for online monitoring and closed-loop parameter adjustment of cutting quality.

[0018] This invention features a contour detection unit installed between two conveyor roller frames, mounted on a frame. The unit comprises an upper laser contour scanner and a lower laser contour scanner, arranged opposite each other to form a contour detection path. As the cut blank passes through this path, the upper and lower laser contour scanners simultaneously collect contour data from its upper and lower surfaces. The acquired contour data is compared with a standard model by a control box and promptly fed back to the tension adjustment unit and the feeding unit, forming an automatic correction loop for cutting parameters. This effectively overcomes the drawbacks of traditional equipment, such as delayed detection and reliance on manual experience for parameter adjustment. The device maintains stable cutting quality even during long-term continuous operation, thus meeting the practical needs of large-scale, high-precision production of aerated concrete blocks.

[0019] This invention includes a first conveyor roller frame and a second conveyor roller frame installed inside the frame. The first conveyor roller frame smoothly transports the billet to the location of the pushing unit, while the second conveyor roller frame receives and guides the billet cut by the cutting section. Since both the first and second conveyor roller frames adopt a low-friction roller structure and are fixedly connected to the frame of the machine, they do not generate additional vibration during operation. Together with the cutting section, they form a stable static cutting environment, further suppressing the cutting surface defects caused by the disturbance of moving parts of the equipment. At the same time, the gap design between the rollers takes into account both the support strength of the billet and the natural fall and discharge of debris, avoiding secondary damage to subsequent billets caused by accumulated material. In addition, the cooperation between the first and second conveyor roller frames can also realize the continuous cutting and processing of aerated concrete blocks. Attached Figure Description

[0020] Figure 1 This is a perspective view of the overall installation structure of the present invention; Figure 2 This is a schematic diagram of the installation structure of the feeding unit in this invention; Figure 3 This is a schematic diagram of the transmission part connection structure in this invention; Figure 4 This is a schematic diagram of the specific structure of the pusher section in this invention; Figure 5 This is the main view of the overall structure in this invention; Figure 6 This is the present invention. Figure 1 Enlarged schematic diagram of the structure at point A in the middle; Figure 7 This is a schematic diagram of the cutting section structure in this invention; Figure 8 This is a schematic diagram of the shaft mounting structure in this invention; Figure 9 This is a schematic diagram of the upper mounting part structure in this invention; Figure 10 This is a schematic diagram of the upper fixed base installation structure in this invention; Figure 11 This is a schematic diagram of the tension detection unit structure in this invention; Figure 12 This is the present invention. Figure 7 Enlarged schematic diagram of the structure at point B; Figure 13 This is a front view of the mounting structure of the contour detection unit in this invention; Figure 14 This is a schematic diagram of the laser contour scanner arrangement structure in this invention; Figure 15 This is a flowchart of the cutting method in this invention; Figure 16 This is a block diagram of the control line system in this invention.

[0021] The attached diagram lists the components represented by each number as follows: 1. Frame; 2. Conveyor roller frame one; 3. Conveyor roller frame two; 4. Pushing unit; 41. Mounting frame; 42. Drive unit; 421. Drive motor; 422. Transmission box; 423. First swing arm; 43. Transmission unit; 431. First tie rod; 432. Swing frame; 433. Second tie rod; 44. Pushing unit; 441. Moving frame; 442. Hinge seat; 443. Pushing plate; 444. Side plate; 445. Guide frame; 5. Tension detection unit; 51. Fixing rod; 52. Through-shaft tension sensor; 53. Limiting wheel; 54. Fixing hole; 6. Contour detection unit; 61. Lower mounting base; 611. Horizontal sliding surface; 612. Inclined surface one; 613. Inclined surface two; 62. Upper mounting base; 63. Upper laser contour scanner; 64. Lower laser contour scanner; 65. Contour detection path; 7. Tension adjustment unit; 71. Fixing frame; 72. Cylinder; 73. Second swing arm; 8. Cutting section; 81. Rotating shaft; 82. Upper mounting section; 821. Sleeve; 822. Connecting plate; 823. Screw; 824. Fixing nut; 825. Adjusting sleeve; 826. Connecting plate; 827. Upper fixed seat; 828. Hinge shaft; 829. Limiting groove; 83. Cutting wire; 84. Side limiting bracket; 9. Lower mounting section; 91. Mounting plate; 92. Through groove; 93. Fixing plate; 94. Lower fixing seat; 10. Control box. Detailed Implementation

[0022] To make the objectives and advantages of this invention clearer, the invention will be specifically described below with reference to embodiments. It should be understood that the following text is merely used to describe one or more specific embodiments of the invention and does not strictly limit the scope of protection specifically claimed by the invention.

[0023] Example 1:

[0024] like Figure 1-14 As shown, an aerated concrete block cutting device includes a frame 1, a first conveyor roller frame 2 for feeding aerated concrete blocks, a second conveyor roller frame 3 for unloading aerated concrete blocks, and a cutting section 8 for cutting aerated concrete blocks is provided between the first conveyor roller frame 2 and the second conveyor roller frame 3.

[0025] Furthermore, the conveyor roller frame 2 is located on one side of the cutting section 8, so the conveyor roller frame 2 can smoothly convey the blank to the working range of the pushing unit 4, and the pushing unit 4 pushes the blank through the cutting section 8 at a uniform speed to complete the fixed width cutting.

[0026] Furthermore, the second conveyor roller frame 3 is located on the other side of the cutting section 8, so the blank after being cut by the cutting section 8 can fall onto the second conveyor roller frame 3 and continue to flow to the next processing step through the second conveyor roller frame 3.

[0027] Both conveyor roller frame 12 and conveyor roller frame 23 adopt a low-friction roller structure, so they do not generate additional vibration during operation and can form a static cutting environment together with the cutting part 8, thereby improving the flatness and dimensional consistency of the cutting surface.

[0028] Meanwhile, since multiple rollers are installed inside conveyor roller frame 1 2 and conveyor roller frame 2 3, and there is a certain gap between the rollers, the gap design allows the cutting chips to fall and be discharged naturally, preventing the accumulated material from causing secondary damage to the subsequent blanks, thereby further ensuring the quality of the cut surface and the stability of the production line operation.

[0029] It should be noted that the cooperation between conveyor roller frame 12 and conveyor roller frame 23 not only achieves continuous conveying and smooth transition of the blank before and after cutting, but also eliminates the need for frequent start-up and shutdown of the equipment during the entire cutting process, significantly reducing energy consumption and mechanical wear.

[0030] See attached document Figure 1 and Figures 5 to 7 A control box 10 is fixedly installed on one side of the frame 1. The control box 10 is electrically connected to the feeding unit 4, the tension detection unit 5, the contour detection unit 6 and the tension adjustment unit 7, and is used to control the collaborative operation and data interaction of each execution unit.

[0031] Specifically, the control box 10 can receive contour data collected by the contour detection unit 6 and tension signals monitored by the tension detection unit 5, and after internal logic calculation, send adjustment commands to the tension adjustment unit 7 so that the tension of the cutting wire 83 is always in the optimal range.

[0032] Meanwhile, the pushing speed of the pushing unit 4 can be adjusted according to the actual size deviation of the blank, so as to ensure that each batch of blocks meets the preset standards in terms of cutting width and surface quality.

[0033] In actual operation, operators can set process parameters through the human-machine interface of the control box 10, and the system will automatically complete the closed-loop control of the entire process from billet conveying and cutting to online detection and parameter feedback, which greatly reduces the reliance on skilled workers.

[0034] In addition, when the tension detection unit 5 detects abnormal fluctuations in the wire tension, the control box 10 will immediately link with the tension adjustment unit 7 to compensate and record the fault information simultaneously, which facilitates later traceability and maintenance and further improves the reliability of the device in continuous production.

[0035] As can be added, an audible and visual alarm can also be installed inside the control box 10 to issue a warning when the wire tension exceeds the safety threshold or the contour detection deviation continues to exceed the limit, so as to remind on-site personnel to intervene and investigate in a timely manner.

[0036] See attached document Figure 1 , Figure 13 and Figure 14 Inside the frame 1, a lower mounting base 61 and an upper mounting base 62 are fixedly installed. Multiple upper laser contour scanners 63 are installed inside the lower mounting base 61, while multiple lower laser contour scanners 64 are installed inside the upper mounting base 62. The multiple upper laser contour scanners 63 and multiple lower laser contour scanners 64 are arranged opposite to each other and form a contour detection path 65.

[0037] According to the above structure, multiple upper laser contour scanners 63 and multiple lower laser contour scanners 64 are electrically connected to the control box 10, enabling them to upload the collected upper and lower surface contour data to the control box 10 for processing in real time.

[0038] During the actual cutting process, when the blank smoothly passes through the contour detection path 65 defined by the upper laser contour scanner 63 and the lower laser contour scanner 64 under the push of the pusher unit 4, the upper laser contour scanner 63 and the lower laser contour scanner 64 can simultaneously acquire its full-width contour information, and perform deviation analysis with the standard model through the comparison algorithm inside the control box 10.

[0039] If dimensional deviations or abnormal cut surface morphology are detected, the control box 10 will automatically generate correction commands and feed them back to the feeding unit 4 and the tension adjustment unit 7, thereby achieving dynamic optimization of cutting parameters and ensuring that the device still has high consistency in processing under high-speed production line conditions.

[0040] As can be further explained, the surface of the lower mounting base 61 is provided with a horizontal sliding surface 611, an inclined surface one 612 and an inclined surface two 613. The inclined surface one 612 and the inclined surface two 613 enable the blank to smoothly transition between the conveyor roller frame one 2 and the conveyor roller frame two 3, avoiding edge chipping or corner damage caused by sharp edges.

[0041] See attached document Figures 1 to 4 A mounting bracket 41 is welded to one side of the frame 1, and a drive unit 42 is fixedly mounted on one side of the mounting bracket 41 by bolts. One side of the drive unit 42 is hinged to the pusher unit 44 through the transmission unit 43, and the pusher unit 44 is slidably mounted to the frame 1. Therefore, by starting the drive unit 42, the pusher unit 44 can be driven to reciprocate linearly along the width direction of the conveyor roller frame 2 to push the blank.

[0042] Specifically, the drive unit 42 includes a drive motor 421 and a first swing arm 423 driven by its output end through a transmission box 422. During rotation, the first swing arm 423 pulls the swing frame 432 to swing through the first pull rod 431, thereby causing the swing frame 432 to drive the moving frame 441 to move smoothly along the guide frame 445 through the second pull rod 433.

[0043] More specifically, the movable frame 441 is slidably installed on the frame 1 via the guide frame 445. Therefore, the movement direction of the movable frame 441 can be restricted by the cooperation between the guide frame 445 and the frame 1.

[0044] Meanwhile, a pusher plate 443 is fixedly installed on the side of the movable frame 441 facing the cutting section 8, and a side plate 444 is fixedly installed on one side of the pusher plate 443. Therefore, the side plate 444 can limit the side of the blank conveyed by the conveyor roller frame 2. At the same time, the movable frame 441 drives the pusher plate 443 to move and send the blank to the cutting section 8 for cutting.

[0045] Meanwhile, a hinge seat 442 is welded on the side of the moving frame 441 facing the transmission part 43. The hinge seat 442 is rotatably hinged to the second pull rod 433. Therefore, when the second pull rod 433 swings with the swing frame 432, the hinge seat 442 can convert the rotational motion into the linear displacement of the moving frame 441, ensuring that the pusher plate 443 accurately pushes the blank to the cutting station with a constant stroke.

[0046] As a supplementary note, the side plate 444 adopts a detachable structure, which facilitates quick replacement according to the block specifications to adapt to the positioning requirements of blanks of different widths.

[0047] See attached document Figure 1 and Figures 6 to 8 A rotating shaft 81 is rotatably installed inside the frame 1, and multiple upper mounting parts 82 are sequentially sleeved on the outside of the rotating shaft 81 along the axial direction of the rotating shaft 81, as well as side limiting frames 84 provided at both ends of the multiple upper mounting parts 82.

[0048] According to the above structure, multiple upper mounting parts 82 are used to fix the upper ends of multiple cutting wires 83, while the lower ends of multiple cutting wires 83 are fixed to the lower mounting part 9, thereby forming a set of parallel arrays of cutting wires 83 to achieve fixed-width cutting of the blank.

[0049] Specifically, a continuous keyway along the axial direction of the shaft 81 is provided on the surface of the shaft 81, and a key block can be installed inside the upper mounting part 82. Through the engagement of the key block and the keyway, the upper mounting part 82 can slide on the surface of the shaft 81 along the axial direction of the shaft 81.

[0050] More specifically, through the cooperation of the key block and the keyway, when the tension adjustment part 7 drives the rotating shaft 81 to rotate, the upper mounting part 82 can rotate synchronously with the rotating shaft 81, thereby driving the upper end of the cutting wire 83 fixed thereon to swing together, so as to realize the dynamic adjustment of the tension of the cutting wire 83.

[0051] See attached document Figures 7 to 10 The upper mounting part 82 includes a sleeve 821 that is keyed to the rotating shaft 81, and connecting discs 822 are welded to both ends of the sleeve 821. At the same time, a fixing nut 824 is welded to the inner side of the connecting disc 822.

[0052] According to the above structure, two adjacent sets of sleeves 821 are connected together by a screw 823. The two ends of the screw 823 are threadedly installed with fixing nuts 824 on the two sets of sleeves 821 respectively. At the same time, an adjusting sleeve 825 is welded to the middle of the screw 823. Therefore, the screw 823 can be driven to rotate by a special tool. By cooperating with the fixing nut 824 and the connecting plate 822, the distance between the two sets of adjacent sleeves 821 can be adjusted.

[0053] Furthermore, a connecting plate 826 is welded to the outside of the sleeve 821, and one side of the connecting plate 826 is installed with the upper end of the cutting wire 83 through the upper fixing seat 827. Therefore, when the sleeve 821 is adjusted, the upper end of the cutting wire 83 can be adjusted, thereby adjusting the cutting width.

[0054] Furthermore, the lower end of the cutting wire 83 is fixedly installed with the lower fixed seat 94, and the lower fixed seat 94 is slidably installed with the mounting plate 91 through the through groove 92. At the same time, the mounting plate 91 is welded to the frame 1, and fixing plates 93 are welded to both sides of the lower fixed seat 94. Therefore, the lower fixed seat 94 and the mounting plate 91 can be fixed by using locking bolts, thereby realizing the synchronous adjustment of the lower end of the cutting wire 83.

[0055] It is worth noting that the upper mounting part 82 and the lower mounting part 9 can drive the upper and lower ends of the cutting wire 83 to be adjusted independently. This design of independent adjustment of the upper and lower ends allows the operator to flexibly change the tilt angle or overall spacing of the wire array according to the actual cutting needs, thereby adapting to the cutting requirements of blocks of different specifications.

[0056] It should be noted that an arc-shaped limiting groove 829 is provided on the surface of the connecting plate 826, and the upper fixing seat 827 is rotatably mounted on the surface of the connecting plate 826 via the hinge shaft 828. At the same time, a connecting threaded rod (not marked in the figure) can be inserted into the inside of the upper fixing seat 827, and a nut can be threaded onto the outside of the connecting threaded rod, with the nut located on the other side of the connecting plate 826. Therefore, when installing the cutting wire 83, the upper end of the cutting wire 83 can be pre-tightened by rotating the upper fixing seat 827, thereby facilitating the adjustment of the spacing of the cutting wire 83 array.

[0057] See attached document Figure 7 and Figure 8 The tension adjustment unit 7 is fixedly installed at the end of the rotating shaft 81, and the fixing frame 71 of the tension adjustment unit 7 is fixedly installed with the frame 1. At the same time, a cylinder 72 is rotatably hinged inside the fixing frame 71, and the output shaft of the cylinder 72 is hinged to the second swing arm 73.

[0058] Furthermore, the second swing arm 73 adopts an eccentric wheel structure, with its rotation center fixedly installed with the rotating shaft 81, and its outer edge hinged to the output end of the cylinder 72.

[0059] Furthermore, when the second swing arm 73 rotates around the rotation center under the drive of the cylinder 72, the displacement change of the outer edge of the eccentric wheel will be directly converted into torque output to the rotating shaft 81, thereby causing the rotating shaft 81 to deflect slightly at an angle.

[0060] Specifically, since the upper mounting part 82 is synchronized with the continuous keyway on the rotating shaft 81 through the key block, the deflection is transmitted to each upper mounting part 82 and the upper end of the cutting wire 83 fixed thereon, causing the wire array to be tensioned or relaxed as a whole.

[0061] This mechanical tensioning mechanism is responsive and requires no additional hydraulic components. Combined with the control box 10's control of the cylinder 72, it can stably maintain the tension of the cutting wire 83 within the optimal range, avoiding wire breakage or cutting deviation caused by sudden changes in the resistance of the billet.

[0062] See attached document Figure 2 , Figure 7 and Figure 11 A tension detection unit 5 is also provided between the cutting section 8 and the lower mounting section 9. The tension detection unit 5 is installed between the frame 1 and the frame 1. The tension detection unit 5 is located near the upper end of the limit wheel 53. Therefore, when the tension adjustment section 7 drives the rotating shaft 81 to swing the upper end of the cutting wire 83 to adjust the tension, the tension can be monitored in real time by the tension detection unit 5.

[0063] According to the above structure, the tension detection unit 5 is fixedly installed on the frame 1 through the through-shaft tension sensor 52, and the fixing rod 51 of the tension detection unit 5 passes through the interior of the through-shaft tension sensor 52. At the same time, a limit wheel 53 is provided on the outside of the fixing rod 51, and the limit wheel 53 is fixed to the fixing rod 51 by bolts and fixing holes 54.

[0064] Specifically, the spacing of the limiting wheel 53 can be adjusted synchronously with the bolt and the fixing hole 54, thereby ensuring that the monitoring point is always aligned with the key stress position of the cutting wire 83 array.

[0065] The through-shaft tension sensor 52 is connected to the control box 10 via a signal cable, so the collected tension value can be uploaded to the control system, where it is fused with the contour data from the contour detection unit 6 by the control box 10.

[0066] When the billet enters the slitting zone and the steel wire experiences a sudden increase in force, the tension detection unit 5 can keenly capture the tension peak and provide feedback. The control box 10 then instructs the tension adjustment unit 7 to make micro-compensation so that the array of cutting steel wires 83 maintains the preset tension.

[0067] Example 2:

[0068] See attached document Figure 1-16 This embodiment, based on the structure of Embodiment 1, further introduces a method for cutting aerated concrete blocks, specifically including the following steps: Step S1, parameter initialization: Before cutting begins, the operator sets the initial feeding speed of the feeding unit 4 via the control box 10. The tension adjustment unit 7 drives the cutting unit 8 to adjust the initial target tension of the cutting wire 83. .

[0069] In this embodiment, the initial feeding speed Set to 1.2 m / min, initial target tension force Set to 150N.

[0070] To improve the accuracy of the initial parameters, this step also includes pre-detection of the billet characteristics: before cutting, a detection rod is inserted into the billet, and the penetration resistance of the detection rod is detected by a pressure sensor. The hardness value of the billet is determined based on the penetration resistance.

[0071] The control box 10 queries the corresponding initial feeding speed from the preset parameter matching table based on the hardness value of the billet. and initial target tension For example, when a high hardness of the billet is detected, a lower initial feeding speed and a higher initial tension are automatically set.

[0072] Step S2, feeding and cutting: Drive unit 42 drives transmission unit 43 to move pusher unit 44 along the width direction of conveyor roller frame 2 at the current pushing speed. (at the time of the first cut) The block blank is pushed to move laterally toward the cutting section 8. The block blank passes through multiple cutting wires 83 fixed on the frame 1, and the cutting wires 83 cut the blank.

[0073] During the cutting process, the through-shaft tension sensor 52 detects the tension of the cutting wire 83 in real time. When the tension deviates from the preset range, the control box 10 controls the tension adjustment unit 7 to move, so that the tension adjustment unit 7 drives the upper mounting part 82 to swing through the rotating shaft 81, thereby pulling the upper end of the cutting wire 83 through the upper mounting part 82 to adjust the tension back to the preset range.

[0074] Step S3, Laser Contour Detection: After the blocks are cut, they are pushed by the pusher unit 4 to the scanning area of ​​the contour detection unit 6. Multiple upper laser contour scanners 63 and lower laser contour scanners 64 simultaneously scan the upper and lower contours of the blank to obtain the actual contour data of the cutting surface, including surface flatness and kerf width.

[0075] Step S4, Profile Analysis and Deviation Calculation: The contour analysis module of control box 10 compares the actual contour data obtained in step S3 with the preset standard contour data and calculates the contour deviation value. In this embodiment, the contour deviation value includes the surface flatness deviation value. and the deviation value of the cut width .

[0076] Surface flatness deviation value The calculation method is as follows: compare the measured height value of each measurement point with the corresponding height value on the standard straight line, and calculate the root mean square of all deviation values. The calculation formula is:

[0077]

[0078] in, This represents the total number of transverse measurement points on the cut surface. For the first The measured height values ​​of each measurement point are in mm. For the first The theoretical height value on the standard profile line at each measurement point, in mm; This represents the surface flatness deviation value, in mm.

[0079] Cut width deviation The calculation method is as follows: perform edge detection on the cut image, extract the two edge lines of the cut, calculate the distance between the two edge lines as the measured cut width, and subtract the standard cut width to obtain the deviation value. The calculation formula is as follows:

[0080]

[0081] in, The measured kerf width is in mm. Standard kerf width, in mm; This represents the deviation value of the kerf width, in mm. A positive value indicates that the kerf is too wide, and a negative value indicates that the kerf is too narrow.

[0082] Step S5, Quality Judgment and Parameter Adjustment: The contour deviation value calculated in step S4 is compared with the preset quality threshold, and the judgment logic is as follows: like and ( The first preset threshold, (If the second preset threshold is used), the current cutting quality is determined to be qualified. The current process parameters are kept unchanged, and the process proceeds directly to step S6. like If the flatness of the cut surface is deemed unqualified, the speed of the drive motor 421 is controlled by the control box 10 according to the first adjustment step. Reduce the feeding speed, that is: .

[0083] like If the kerf width is deemed unqualified, the tension adjustment unit 7 is controlled by the control box 10 to adjust according to the second adjustment step. Increase the tension setting value, that is: .

[0084] like and Both of the above adjustments will be implemented simultaneously.

[0085] in, The first preset threshold represents the surface flatness deviation value. The maximum allowable value is in mm. The second preset threshold represents the kerf width deviation value. The maximum allowable value is in mm. Exceeding When the surface flatness exceeds the standard, it indicates that the surface flatness is too high; when Exceeding When this occurs, it indicates that the kerf width exceeds the allowable tolerance range.

[0086] In this embodiment, Set to 0.5 mm. Set to 0.3 mm. The first adjustment step size represents the single decrease in the feeding speed, expressed in m / min. In this embodiment... Take 10% of the current feeding speed, that is ; The second adjustment step represents the single increase in tension force, expressed in N. In this embodiment... Take 5% of the current tension, that is: .

[0087] The adjusted parameters must meet the following constraints: feed rate Not lower than the initial feeding speed 50% of, that is: Tension Not exceeding the initial target tension 120% of, that is: This is to prevent the steel wire from breaking or the billet from cracking due to over-adjustment.

[0088] Step S6, execute repeatedly: Return to step S2 and use the adjusted process parameters to cut the next blank, forming a continuous closed-loop control cycle.

[0089] In another preferred embodiment of this example, data recording and trend analysis may be introduced after step S6, specifically including the following steps: After each cut, the feeding speed during the cutting process can be recorded via the storage module inside the control box 10. Tension and the corresponding contour deviation value , Associated storage.

[0090] Meanwhile, the control box 10 can also be equipped with a trend analysis module, which can periodically (e.g., after every 50 blanks are cut) retrieve historical data from the storage module to analyze the tension. and feeding speed Trends over time.

[0091] When tension When the cumulative increase in tension exceeds 30% of the initial tension during 20 consecutive cuts, or when the feed rate... When the cumulative reduction in cutting speed exceeds 40% of the initial feeding speed during 20 consecutive cuts, the control box 10 issues a warning signal to replace the cutting wire 83, reminding the operator to replace the wire to prevent fatigue breakage and further deterioration of cutting quality.

[0092] Specifically, the control box 10 includes: a profile analysis module, a parameter adjustment module, a storage module, a trend analysis module, a power management module, an I / O interface layer, and a human-machine interface.

[0093] Contour Analysis Module: Used to receive the contour data of the cut surface from the contour detection unit 6, compare the contour data with the preset standard contour data, and calculate the contour deviation value.

[0094] Parameter adjustment module: Based on the contour deviation value calculated by the contour analysis module, the tension setting value of the cutting wire 83 and / or the pushing speed of the pushing unit 4 are dynamically adjusted by the tension adjustment unit 7.

[0095] Storage module: Stores the feeding speed data, tension data, and corresponding contour deviation data for each cutting process.

[0096] Trend Analysis Module: Retrieves historical data stored in the storage module to analyze the changing trends of the tension setting of the cutting wire 83 and / or the pushing speed of the pushing unit 4 over time.

[0097] The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described or explained in this invention are implemented according to conventional methods in the art unless otherwise specified or limited.

Claims

1. An aerated concrete block cutting device, characterized in that, include: The machine frame (1), a conveyor roller frame one (2) for feeding aerated concrete blocks, and a conveyor roller frame two (3) for unloading aerated concrete blocks are provided between the conveyor roller frame one (2) and the conveyor roller frame two (3) for cutting aerated concrete blocks. The frame (1) is equipped with a contour detection unit (6) on the side facing the conveyor roller frame (3). The contour detection unit (6) is used to collect the contour data of the aerated concrete block after cutting, and upload the contour data to the control box (10) to compare with the preset contour data and calculate the contour deviation value. The control box (10) drives the tension adjustment unit (7) to adjust the tension of the cutting wire (83) according to the contour deviation value, and drives the drive unit (42) to adjust the pushing speed of the pushing unit (44) through the control box (10).

2. The aerated concrete block cutting device according to claim 1, characterized in that: A drive unit (42) is fixedly installed on one side of the frame (1) by a mounting bracket (41). The drive unit (42) drives the pusher (44) to reciprocate through the transmission unit (43), so that the pusher (44) pushes the aerated concrete block through the cutting wire (83). The drive unit (42) includes a drive motor (421) fixedly installed on one side of the mounting bracket (41). The drive motor (421) drives the first swing arm (423) to rotate through the transmission box (422), so that the first swing arm (423) drives one end of the first pull rod (431) to swing, and drives the swing frame (432) to swing through the other end of the first pull rod (431).

3. The aerated concrete block cutting device according to claim 2, characterized in that: The swing frame (432) is rotatably hinged to the inside of the frame (1), and one side of the swing frame (432) is hinged to the pusher (44) through the second pull rod (433), so that the second pull rod (433) pulls the pusher (44) to slide linearly inside the frame (1); The pusher (44) drives the pusher plate (443) to slide linearly in sync through the moving frame (441), and pushes the aerated concrete block toward the cutting part (8) in a straight line through the pusher plate (443).

4. The aerated concrete block cutting device according to claim 1, characterized in that: A tension adjustment part (7) is fixedly installed on one side of the frame (1). The tension adjustment part (7) is used to drive the cutting part (8) to swing the upper mounting part (82) to rotate, so that the upper mounting part (82) drives the upper end of the cutting wire (83) to move in a fan shape, which is used to adjust the tension of the cutting wire (83). The other end of the cutting wire (83) is fixedly installed to the frame (1) through the lower mounting part (9). The frame (1) is also equipped with a tension detection unit (5). The cutting wire (83) abuts against the surface of the tension detection unit (5) and the tension of the cutting wire (83) is obtained in real time through the tension detection unit (5), and the tension data is transmitted to the control box (10).

5. The aerated concrete block cutting device according to claim 4, characterized in that: The tension adjustment unit (7) includes a fixed frame (71) fixedly installed on one side of the frame (1). The cylinder (72) hinged inside the fixed frame (71) is used to push the second swing arm (73) to move in a fan shape, so that the second swing arm (73) drives the rotating shaft (81) and the upper mounting part (82) to move synchronously. The upper mounting parts (82) are evenly distributed in multiple ways along the axis of the rotating shaft (81), and the side limiting brackets (84) with external threads installed on the rotating shaft (81) are used to abut against the upper mounting parts (82) at both ends to limit and fix the ends of the multiple upper mounting parts (82).

6. The aerated concrete block cutting device according to claim 5, characterized in that: The upper mounting part (82) includes a sleeve (821) that is slidably mounted along the axis of the rotating shaft (81). Connecting discs (822) are mounted at both ends of the sleeve (821). A screw (823) and an adjusting sleeve (825) are provided between the two sets of sleeves (821). The adjusting sleeve (825) is used to drive the screw (823) to rotate inside the fixing nut (824), so that the two sets of sleeves (821) move towards each other. A connecting plate (826) is fixedly connected to the surface of the sleeve (821). One side of the connecting plate (826) is rotatably hinged to an upper fixed seat (827) via a hinge shaft (828). A limiting groove (829) is provided inside the connecting plate (826) so that the upper fixed seat (827) slides along the limiting groove (829) and is fixed by a locking bolt. This is used for fine adjustment of the tension between the upper fixed seat (827) and the end of the cutting wire (83).

7. The aerated concrete block cutting device according to claim 6, characterized in that: The bottom of the cutting wire (83) is fixedly installed with the lower fixing seat (94). The lower fixing seat (94) is slidably installed with the mounting plate (91) through the through groove (92), and the side of the lower fixing seat (94) is locked with the mounting plate (91) through the fixing plate (93). The lower fixing seat (94), the upper mounting part (82), and the cutting wire (83) are provided in multiple sets, and the multiple sets of the lower fixing seat (94) and the upper mounting part (82) are used to drive the multiple sets of cutting wires (83) to adjust the spacing.

8. The aerated concrete block cutting device according to claim 1, characterized in that: A lower mounting base (61) and an upper mounting base (62) are fixedly installed on one side of the frame (1). An upper laser contour scanner (63) and a lower laser contour scanner (64) are respectively installed inside the lower mounting base (61) and the upper mounting base (62). The upper laser contour scanner (63) and the lower laser contour scanner (64) are arranged correspondingly to the cutting wire (83). A contour detection path (65) is provided between the upper laser contour scanner (63) and the lower laser contour scanner (64), so that when the cut aerated concrete block passes through the contour detection path (65), the contour data of the aerated concrete block is collected by the upper laser contour scanner (63) and the lower laser contour scanner (64).

9. A method for cutting aerated concrete blocks, applied to the aerated concrete block cutting device according to any one of claims 1-8, characterized in that, Includes the following steps: Step S1: Set the initial pushing speed of the pushing unit (4) and the initial target tension of the cutting wire (83); Step S2: The pushing unit (4) pushes the aerated concrete block blank through the cutting wire (83) of the cutting part (8) in the transverse direction at the current pushing speed, and the cutting wire (83) cuts the blank; Step S3: After the block is cut, it reaches the scanning area of ​​the contour detection unit (6). The upper and lower contours of the block are scanned by the upper laser contour scanner (63) and the lower laser contour scanner (64) to obtain the actual contour data of the block after cutting. Step S4: The control box (10) compares the actual contour data obtained in step S3 with the preset standard contour data and calculates the contour deviation value; Step S5: Compare the contour deviation value calculated in step S4 with the preset quality threshold of the control box (10): If the contour deviation value is less than or equal to a preset quality threshold, the current process parameters remain unchanged; if the contour deviation value is greater than the preset quality threshold, at least one of the following adjustment operations is performed: When the surface flatness deviation exceeds the first preset threshold, the feeding speed is reduced according to the first adjustment step. When the kerf width deviation exceeds the second preset threshold, the tension setting is increased according to the second adjustment step. Step S6: Return to step S2 and cut the next blank using the adjusted process parameters.

10. The cutting method according to claim 9, characterized in that: In step S1, the initial feeding speed and the initial target tension are set as follows: Before cutting, the blank is pre-tested to obtain the hardness value of the blank. Based on the hardness value of the blank, the corresponding initial feeding speed and initial target tension are queried from the preset parameter matching table. The pre-detection method is as follows: insert the detection rod into the blank, detect the penetration resistance of the detection rod through a pressure sensor, and determine the hardness value of the blank based on the penetration resistance.

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