A ceramic greenware line cutting device and roll forming system

Abstract

The utility model relates to a kind of ceramic biscuit line cutting device and roll forming system.The ceramic biscuit line cutting device in it, including: cutting line;First power unit, for driving cutting line movement;Wherein, by the drive of first power unit, so that cutting line is formed with cutting zone in movement, and cutting line in the cutting zone along Y axis movement, to form sawing tool;And, cutting line can cut along the thickness direction of ceramic biscuit.This application scheme in the cutting stroke of cutting line is the thickness direction of ceramic biscuit, can make that cutting surface flatness and smoothness significantly improve, can effectively improve cutting effect, and also can reduce the generation of waste material.Moreover, cutting stroke reduces, cutting time is greatly shortened, can greatly improve production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of ceramic blank cutting technology, and in particular to a ceramic blank wire cutting device and roll forming system. Background Technology

[0002] The forming process of ceramic brick blanks is the process of transforming dispersed powder or slurry into block-shaped blanks with a certain geometric shape and strength.

[0003] Currently, dry forming processes are the mainstream for ceramic tile blanks. For example, continuous roll forming technology and its equipment involve a pair of opposing cylindrical pressing rollers in the pressing area. The lower roller is fixed in position and rotates around a central axis; the upper roller is driven downwards by a pair of hydraulic cylinders to apply pressure to the powder. A steel belt is used for feeding the ceramic powder, which is then distributed on the lower traction steel belt. The rotating belt feeds the uniformly thick ceramic powder between the pressing rollers. Under hydraulic pressure, the powder is compressed between the rollers and formed into a ceramic blank. The ceramic blank then needs to be transported to a cutting station for slitting.

[0004] However, in actual cutting, it has been found that existing cutting devices have at least the following problems:

[0005] Existing technology uses a high-speed motor to drive a disc-shaped cutting blade to cut the green blank. In practical use, it has been found that the feed speed of the disc-shaped cutting blade relative to the green blank cannot be too fast; otherwise, defects such as edge chipping may occur at the cut edge. Furthermore, the cutting stroke is limited to the width of the green blank being cut, which restricts the brick output speed and consequently limits the production volume of bricks, affecting production efficiency. To improve production efficiency, the feed speed of the disc-shaped cutting blade needs to be increased; however, this again easily leads to edge chipping and other defects at the cut edge, thus reducing the cutting effect.

[0006] Therefore, it is urgent to solve the aforementioned problems. Utility Model Content

[0007] To overcome at least one of the defects described in the prior art, according to one aspect of the present invention, a ceramic green body wire cutting device is provided, comprising:

[0008] Cutting line;

[0009] The first power unit is used to drive the movement of the cutting line;

[0010] The first power unit drives the cutting line to form a cutting area during the movement, and the cutting line in the cutting area moves along the Y-axis to form a sawing tool.

[0011] Furthermore, the cutting line can be made along the thickness direction of the ceramic blank.

[0012] In one embodiment of this application, a conveying unit and a second power unit are also included. The conveying unit is used to convey the ceramic blank along the X-axis, and the second power unit is used to drive the cutting line to move along the X-axis direction.

[0013] When cutting, the second power unit is used to drive the cutting line to move synchronously with the ceramic blank.

[0014] In one embodiment of this application, a third power unit is also included, which is used to drive the cutting line to move along the Z-axis;

[0015] When cutting, the second power unit is used to drive the cutting line to move synchronously with the ceramic blank, and the third power unit is used to drive the cutting line to cut the ceramic blank along the Z-axis.

[0016] In one embodiment of this application, the cutting line is a straight line structure, and the first power unit is used to drive the cutting line itself to perform linear reciprocating motion;

[0017] The first power unit includes a first power wheel and a second power wheel. The two ends of the cutting line are connected to the first power wheel and the second power wheel respectively. The first power wheel and the second power wheel can rotate synchronously in both directions to drive the cutting line to make linear reciprocating motion.

[0018] In one embodiment of this application, the cutting line is a ring structure, and the first power unit is used to drive the cutting line itself to rotate in a ring.

[0019] The first power unit includes a power wheel and a driven wheel, with a cutting line wound between the power wheel and the driven wheel to form a ring-shaped cutting structure.

[0020] In one embodiment of this application, at least one driven wheel is provided, and the position of at least one driven wheel is adjustable to tension the annular cutting line.

[0021] In one embodiment of this application, the number of driven wheels is at least three, and the positions of the three driven wheels and one power wheel are arranged in a quadrilateral cut shape;

[0022] Alternatively, the number of driven wheels is set to at least two, and the positions of the two driven wheels and one driving wheel are arranged in a triangular cut shape.

[0023] In one embodiment of this application, a speed detection unit is also included. The speed detection unit is used to detect the speed of the ceramic blank and feed the speed back to the second power unit so as to drive the cutting line to move synchronously with the ceramic blank through the second power unit.

[0024] In one embodiment of this application, the speed detection unit includes at least one speed detection wheel, and the speed detection wheel is used to measure the speed of the ceramic blank.

[0025] In one embodiment of this application, a frame, a conveying unit, and a second power unit are also mounted on the frame;

[0026] The frame is slidably equipped with a first frame, a second power unit is used to drive the first frame to move relative to the frame along the X-axis, and a third power unit is mounted on the first frame;

[0027] The first frame is slidably mounted on the second frame, and the third power unit is used to drive the second frame to move relative to the first frame along the Z-axis. The first power unit is mounted on the second frame.

[0028] According to another aspect of this application, a roll forming system is provided, including the above-described ceramic blank wire cutting device.

[0029] In summary, the ceramic green body wire cutting device and roll forming system provided by this utility model have the following technical effects:

[0030] The cutting stroke of the cutting line in this application is along the thickness direction of the ceramic blank, which significantly improves the flatness and smoothness of the cut surface, effectively enhancing the cutting effect and reducing waste. Furthermore, the reduced cutting stroke drastically shortens the cutting time, significantly increasing production efficiency. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of a cutting machine in the prior art;

[0032] Figure 2 This is a schematic diagram of the structure of the ceramic blank wire cutting device according to an embodiment of the present invention;

[0033] Figure 3 This is another structural schematic diagram of the ceramic blank wire cutting device according to an embodiment of the present utility model;

[0034] Figure 4 This is another structural schematic diagram of the ceramic blank wire cutting device according to an embodiment of the present utility model;

[0035] Figure 5 This is a schematic diagram of the cutting line and the structure of the first power unit in the ceramic blank wire cutting device according to an embodiment of the present invention.

[0036] Attached Figure: 1-Cutting line, 21-Power wheel, 22-Driven wheel, 3-Speed ​​detector wheel, 41-Frame, 42-First frame, 43-Second frame, 51-Driven roller, 52-Driven roller, 53-Conveyor belt, 61-Transverse slide rail, 62-Transverse slider, 63-Vertical slide rail, 64-Vertical slider, 71-First motor, 72-First telescopic cylinder, 8-Ceramic blank, 9-Disc-shaped cutting blade. Detailed Implementation

[0037] To better understand and implement this invention, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0038] In the description of this utility model, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0040] An embodiment of this utility model discloses a wire cutting device for ceramic blanks.

[0041] In one or more embodiments, such as Figures 2-5 As shown, the ceramic blank wire cutting device includes a cutting line 1 and a first power unit.

[0042] The cutting line 1 is used to cut the ceramic blank 8.

[0043] The first power unit drives the cutting line 1 to move. Driven by the first power unit, the cutting line 1 forms a cutting zone during its movement, and within this cutting zone, the cutting line 1 moves along the Y-axis to function as a sawing tool. It should be noted that the cutting zone formed by the cutting line 1 during its movement refers to the area where the cutting line 1 contacts and cuts the ceramic blank 8. This area dynamically forms along the trajectory of the cutting line 1 and is a key part for completing the cutting of the ceramic blank 8.

[0044] Furthermore, the cutting line 1 can cut along the thickness direction of the ceramic blank 8. It should be noted that the ceramic blank 8 being cut is a compacted ceramic blank 8.

[0045] To better understand the inventive concept of this application, let me first briefly describe the improvement ideas in the research and development process:

[0046] In existing ceramic tile production lines, the pressed ceramic blanks 8 are cut by a high-speed motor driving a disc-shaped cutting blade 9.

[0047] To avoid defects such as chipping at the cut edges of the green blank during cutting, the feed speed Vy of the disc-shaped cutting blade 9 relative to the green blank cannot be too fast; for example, Vy ≤ 25 m / min. The ceramic green blank is continuously conveyed along the brick exit direction (X direction) at a speed Vx. The operating speed of the existing cutting machine can then be decomposed into Vx = V*sinθ and Vy = V*cosθ, as follows... Figure 1 As shown, when the feed rate Vy is limited, the brick output rate Vx will also be limited, meaning the production output of brick blanks is restricted.

[0048] To improve production efficiency, the feed speed of the disc-shaped cutting blade 9 can be increased. However, this can easily lead to defects such as chipping at the cutting edge of the blank, thereby reducing the cutting effect.

[0049] Alternatively, the angle θ can be adjusted. For example, increasing the angle θ can increase the upper limit of the brick output speed Vx to some extent, but at the same time, the X-axis stroke of the existing cutting machine also needs to be increased accordingly, resulting in a larger size of the cutting machine in the X-axis and a larger space occupation. Furthermore, increasing the angle θ will cause the cutting head of the existing cutting machine to run at a higher speed along the cutting guide rail. The excessively high speed will place higher power and vibration reduction requirements on the equipment, increasing the equipment cost.

[0050] In addition, the disc-shaped cutting blade 9 is prone to wear when cutting brick blanks. When the wear is large, the cutting effect of the disc-shaped cutting blade 9 deteriorates, and the disc-shaped cutting blade 9 needs to be replaced. Due to its structure, the replacement time is long and the replacement frequency is high, which affects the customer's production efficiency and increases the customer's usage cost.

[0051] Furthermore, in actual cutting, multiple high-speed motors are required to drive the disc-shaped cutting blade 9, resulting in high costs. Additionally, the high-speed rotating disc-shaped cutting blade 9 generates significant noise when cutting the blank, impacting worker health.

[0052] Based on the above-mentioned problems and reasons, the applicant has developed the solution of the embodiment of this application after in-depth research. Instead of using the disc-shaped cutting blade 9 in the prior art, the applicant uses the cutting line 1 to cut the ceramic blank 8.

[0053] In practical use, the cutting line 1 is driven to move by the first power unit. The first power unit drives the cutting line 1 to form a cutting area during its movement, and the cutting line 1 within this cutting area moves along the Y-axis to function as a sawing tool. Figure 2 As shown. It should be noted that the first power unit drives the cutting line 1 to move. This movement means that the cutting line 1 itself will move along the Y-axis. For example, the cutting line 1 itself will rotate in a circle or move in a reciprocating linear motion along the Y-axis. The cutting line 1 itself will be shaped into a sawing tool to cut the ceramic blank 8.

[0054] Furthermore, in order to improve cutting efficiency, the solution of this application no longer uses the cutting along the width direction of the ceramic blank 8 as in the prior art, but innovatively uses the cutting along the thickness direction of the ceramic blank 8.

[0055] Because the internal structure of the ceramic blank 8 is anisotropic after compaction, and the interlayer bonding force along the width direction of the ceramic blank 8 is relatively weak, existing technologies often result in defects such as delamination and edge chipping on the cut surface when cutting along the width direction of the ceramic blank 8 due to insufficient interlayer bonding force. This solution, however, uses cutting along the thickness direction of the ceramic blank 8, utilizing its relatively compact structural characteristics in that direction. During the cutting process, the cutting tool cuts along the thickness direction; since the structural integrity is better in this direction, it effectively reduces the damage to the blank structure caused by cutting stress.

[0056] Therefore, compared to cutting along the width direction, cutting along the thickness direction effectively avoids the problem of weak interlayer bonding, greatly reduces the generation of defects such as delamination and chipping on the cut surface, significantly improves the flatness and smoothness of the cut surface, effectively improves the cutting effect, and also reduces the generation of waste, laying a good foundation for the subsequent processing and performance of ceramic products.

[0057] In summary, the cutting stroke of the cutting line 1 in this application is along the thickness direction of the ceramic blank 8, thus reducing the cutting stroke and significantly shortening the cutting time. Furthermore, by using the cutting line 1 to cut the ceramic blank 8, since the ceramic blank 8 has a large width and a small thickness, in actual cutting, the cutting line 1 can contact the surface of the ceramic blank 8 along the width direction along the Y-axis, and then cut along the thickness direction (Z-axis) of the ceramic blank 8. Because the thickness direction (Z-axis) dimension of the ceramic blank 8 is small, the cutting stroke is short, therefore the cutting time is very short, significantly reducing the required cutting time.

[0058] More importantly, the cutting stroke is along the thickness direction of the ceramic blank 8, which significantly improves the cutting efficiency, especially for large-sized ceramic blanks 8. For example, when producing a ceramic blank 8 that is 1830mm wide and 10mm thick, the cutting stroke can be shortened to less than 0.5%, which can greatly improve production efficiency. This is an effect that cannot be achieved by using a disc-shaped cutting blade 9 in the existing technology.

[0059] Furthermore, by using the cutting line 1 to replace the disc-shaped cutting blade 9 in the existing technology, the problem of disc surface deformation of the disc-shaped cutting blade 9 is eliminated, which can ensure the cutting effect well.

[0060] Furthermore, the cutting wire 1 is inexpensive, requires a low-speed drive motor, has low vibration, low wear, and low replacement frequency, thus reducing the manufacturing cost of the equipment. For example, a common three-phase motor can be used to drive the cutting wire 1, which does not require high motor specifications; moreover, only one motor (such as the first motor 71 in the figure) can be used to drive the cutting wire 1, significantly reducing costs.

[0061] Furthermore, the principle of cutting the ceramic blank 8 using the cutting line 1 differs from traditional blade cutting. When cutting the ceramic blank 8, the cutting line 1 relies on the friction generated between its high-speed contact with the surface of the ceramic blank 8, achieving material removal through the grinding action of the abrasive. Compared to the cutting of existing disc-shaped cutting blades 9, the cutting line 1 does not rely on direct compression and shearing from a sharp edge, but rather utilizes tiny abrasive grains distributed on the cutting line 1 to gradually grind the blank at a high frequency and with a small contact area. During the process, the flexible nature of the cutting line 1 allows it to buffer the cutting force and reduce vibrations caused by rigid collisions. This unique cutting method fundamentally reduces the source of noise generation, greatly improves the workshop working environment, effectively reduces occupational health risks for workers, and decreases the probability of occupational diseases such as hearing loss and tinnitus.

[0062] In one or more embodiments, the cutting wire 1 may be made of a high-strength, high-wear-resistant alloy wire, preferably an alloy material containing metallic elements such as tungsten and molybdenum. Such alloy materials possess excellent hardness and toughness, enabling them to maintain a stable shape during the cutting of the ceramic blank 8, reducing wear and extending service life. Alternatively, the surface of the alloy wire may be treated with a special coating, which is composed of nano-sized diamond particles and a high-temperature resistant, low-friction coefficient resin material. This coating further enhances the wear resistance of the cutting wire 1 and reduces the friction between the cutting wire 1 and the ceramic blank 8 during the cutting process, preventing damage to the surface of the ceramic blank 8 caused by the high temperature generated by friction, and ensuring the flatness and smoothness of the cut surface.

[0063] In one or more embodiments, such as Figures 2-4 As shown, the ceramic blank wire cutting device also includes a conveying unit and a second power unit.

[0064] The conveying unit is used to convey the ceramic blank 8 along the X-axis.

[0065] The second power unit is used to drive the cutting line 1 to move along the X-axis.

[0066] When cutting, the second power unit is used to drive the cutting line 1 to move synchronously with the ceramic blank 8.

[0067] It should be noted that, in order to further improve production efficiency, the conveying unit can continuously and uninterruptedly convey the ceramic blank 8, and the cutting line 1 of the present application can continuously cut on the continuously moving ceramic blank 8, so as to realize the continuous cutting of the ceramic blank 8 and improve the ceramic production efficiency.

[0068] In practical use, the conveying unit continuously conveys the ceramic blank 8. During this conveying process, the first power unit drives the cutting line 1 to move, so that the cutting line 1 forms a cutting area during the movement, and the cutting line 1 in the cutting area moves along the Y-axis to form a sawing tool.

[0069] Furthermore, the second power unit drives the cutting line 1 to move along the X-axis. It should be noted that the second power unit drives the cutting line 1 to move synchronously with the ceramic blank 8. This synchronous movement means that the cutting line 1 and the conveyed ceramic blank 8 move at the same speed and in the same direction, forming a relatively static working state.

[0070] Therefore, in the actual cutting process, the ceramic blank 8 is constantly moving along the conveying direction. In order to achieve cutting while the ceramic blank 8 is constantly moving, the solution of this embodiment uses a second power unit to drive the cutting line 1 to move synchronously with the ceramic blank 8. That is, during cutting, the cutting line 1 moves with the ceramic blank 8 and is cut while maintaining the same speed and direction as the ceramic blank 8.

[0071] With this configuration, during the cutting process, the second power unit drives the cutting line 1 and the ceramic blank 8 to move synchronously along the X-axis, so that the cutting line 1 and the ceramic blank 8 always remain relatively stationary. This effectively avoids cutting offset or vibration caused by the difference in relative motion speed between the two, thereby enabling millimeter-level or even higher precision cutting, meeting the stringent requirements of ceramic products for dimensional accuracy.

[0072] It should be noted that, due to the limited feed speed of existing cutting machines, a larger dimension is required in the X-axis, resulting in a larger footprint. In contrast, the solution in this embodiment, thanks to a significantly reduced cutting time, results in a smaller X-axis distance, making the overall length of the machine significantly smaller than that of traditional cutting machines. This miniaturization significantly reduces the space required, effectively reducing floor space in modern factories where space is at a premium, saving companies on land rental or construction costs. Furthermore, the more compact layout allows companies to flexibly adjust equipment arrangement in the workshop according to production needs, improving space utilization.

[0073] Meanwhile, the smaller overall size eliminates the need for specialized large transport vehicles during transportation, reducing transportation difficulty and costs. Installation also requires no large area, and the more compact structure simplifies the installation process, reducing installation time and labor costs, allowing companies to start production more quickly. Furthermore, the miniaturized cutting device can be easily integrated into automated ceramic production lines, seamlessly connecting with other production equipment for a smooth workflow. This high degree of integration not only improves the overall automation level of the production line but also reduces wasted space between devices, further optimizing production layout and improving production efficiency and management convenience.

[0074] In one or more embodiments, the second power unit may specifically be a telescopic motor or a telescopic cylinder. For example, when a telescopic motor is used as the second power unit, a ball screw type electric actuator structure may be adopted. Alternatively, when a telescopic cylinder is used as the second power unit, a double-acting piston cylinder structure may be adopted.

[0075] In one or more embodiments, the conveying unit may specifically include a drive roller 51, a driven roller 52, and a conveyor belt 53 tensioned between the drive roller 51 and the driven roller. The drive roller 51 is connected to a servo motor as a power source. With this configuration, the ceramic blank 8 is conveyed via the drive roller 51, the driven roller 52, the conveyor belt 53, and the servo motor. This structure is simple, easy to manufacture, and reduces manufacturing costs.

[0076] Alternatively, in one or more other embodiments, the conveying unit may also include a roller conveyor that performs horizontal transport by driving multiple rollers to convey the ceramic blank 8.

[0077] In one or more embodiments, the ceramic blank wire cutting device further includes a third power unit for driving the cutting wire 1 to move along the Z-axis; when cutting, the second power unit is used to drive the cutting wire 1 to move synchronously with the ceramic blank 8, and the third power unit is used to drive the cutting wire 1 to cut the ceramic blank 8 along the Z-axis direction.

[0078] When the cutting operation starts, the second power unit comes into play, driving the cutting line 1 to move synchronously with the ceramic blank 8. This design ensures that the cutting line 1 can move synchronously with the ceramic blank 8, avoiding the cutting line 1 from separating from the ceramic blank 8 or the cutting misalignment due to speed differences.

[0079] Furthermore, the third power unit drives the cutting line 1 to move along the Z-axis. This Z-axis movement allows the cutting line 1 to penetrate deeply into the ceramic blank 8. As the cutting line 1 advances along the Z-axis and moves synchronously with the ceramic blank 8, it gradually cuts the ceramic blank 8 along the predetermined cutting path. Throughout the cutting process, the second and third power units cooperate. The second power unit ensures the relative position of the cutting line 1 and the ceramic blank 8 remains stable, while the third power unit performs the cutting action of the cutting line 1 in the vertical direction. These two units complement each other, thus achieving precise cutting of the ceramic blank 8.

[0080] This configuration allows the cutting line 1 to move synchronously with the ceramic blank 8. Combined with precise control of the cutting line 1 along the Z-axis, it effectively reduces cutting deviations, ensuring a smooth and flat cut surface. This results in higher dimensional accuracy for the cut ceramic blank 8, meeting the processing requirements of complex ceramic products and satisfying the quality standards for high-quality ceramic production. Furthermore, the coordinated operation of the second and third power units makes the cutting process continuous and efficient, enabling rapid completion of the cutting of the ceramic blank 8, shortening the processing time, increasing the overall capacity of the production line, and reducing production costs.

[0081] In one or more embodiments, the third power unit may specifically be a telescopic motor or a telescopic cylinder. For example, when a telescopic motor is used as the third power unit, a ball screw type electric actuator structure may be adopted. Alternatively, when a telescopic cylinder is used as the third power unit, a double-acting piston cylinder structure may be adopted. In the illustrated embodiment, it may be a first telescopic cylinder 72.

[0082] In one or more embodiments, the cutting line 1 is a straight structure, and the first power unit is used to drive the cutting line 1 to perform linear reciprocating motion. The first power unit includes a first power wheel 21 and a second power wheel 21. The two ends of the cutting line 1 are connected to the first power wheel 21 and the second power wheel 21 respectively. The first power wheel 21 and the second power wheel 21 can rotate synchronously in both directions to drive the cutting line 1 to perform linear reciprocating motion.

[0083] In this embodiment, the two ends of the cutting line 1 are fixedly connected to the first power wheel 21 and the second power wheel 21, forming a closed motion loop. When the cutting device is started, the first power wheel 21 and the second power wheel 21 can rotate synchronously in both directions.

[0084] For example, the first and second drive wheels rotate clockwise, and through the friction of the wheels on the cutting line 1, the cutting line 1 moves rapidly laterally along a straight line. When the drive wheel 21 receives a reverse rotation command, the first and second drive wheels 21 rotate counterclockwise, and the cutting line 1 moves in the opposite direction, thus completing one cycle of linear reciprocating motion. By precisely controlling the speed, direction switching frequency, and rotation angle of the drive wheel 21, the cutting line 1 can perform stable linear reciprocating motion at a set speed, stroke, and frequency, achieving efficient cutting of the cutting line 1.

[0085] Therefore, the linear reciprocating motion mode of cutting line 1 can significantly shorten the single cutting cycle and significantly improve the cutting efficiency per unit time. At the same time, the high-frequency reciprocating motion, combined with cutting line 1, can quickly cut the ceramic blank 8, making it suitable for large-scale production scenarios. Furthermore, the use of dual-drive wheels 21 ensures that the cutting line 1 is subjected to more uniform force, avoiding potential problems such as cutting line 1 deviation and vibration, ensuring the stability and reliability of the cutting process, extending the service life of cutting line 1, and reducing equipment maintenance costs.

[0086] In one or more embodiments, the cutting line 1 is a ring structure, and the first power unit is used to drive the cutting line 1 to rotate in a ring. The first power unit includes a power wheel 21 and a driven wheel 22, and the cutting line 1 is wound between the power wheel 21 and the driven wheel 22 to form a ring cutting structure.

[0087] During cutting, the power wheel 21 in the first power unit begins to rotate under the drive of an external drive device (such as a motor). Through friction with the cutting wire 1, the power wheel 21 transmits rotational power to the cutting wire 1, driving it to begin moving. The cutting wire 1 is wound between the power wheel 21 and the driven wheel 22. The driven wheel 22 provides support and guidance, helping to maintain the circular structure and stable operation of the cutting wire 1. As the power wheel 21 continues to rotate, the cutting wire 1, under the traction of the power wheel 21, continuously circulates along the circular track, forming a continuously high-speed cutting structure. In actual cutting operations, the high-speed moving cutting wire 1 cuts the ceramic blank 8 through friction and cutting, utilizing the continuous cutting force generated by the circular rotation of the cutting wire 1 to achieve efficient cutting of the ceramic blank 8.

[0088] This configuration allows the continuous rotation of the annular cutting line 1 to cut the material without interruption, avoiding the time loss caused by frequent tool starts and stops in traditional cutting methods, thus significantly improving cutting efficiency. It is particularly suitable for large-scale, continuous cutting operations. Furthermore, because the cutting line 1 always maintains annular rotation, the cutting force is evenly distributed during the cutting process, effectively reducing unevenness and burrs on the cut surface of the ceramic blank 8, improving cutting accuracy and surface quality, and reducing subsequent processing costs.

[0089] Furthermore, the annular structure ensures that the cutting line 1 is subjected to uniform force in all parts during operation, avoiding excessive local wear. Compared with cutting tools, the service life of the annular cutting line 1 is significantly extended, reducing the frequency of tool replacement and maintenance costs.

[0090] In one or more embodiments, at least one driven wheel 22 is provided, and the position of at least one driven wheel 22 is adjustable to tension the annular cutting line 1.

[0091] In this cutting system, the annular cutting line 1 is mounted on the driving wheel and at least one driven wheel 22. The driving wheel is driven to rotate by an external drive device (such as a motor) to provide motion power for the cutting line 1.

[0092] When there is only one driven wheel 22, by adjusting its position, the wrap angle and line length of the cutting line 1 between the driving wheel and the driven wheel 22 can be changed, thereby adjusting the tension.

[0093] If there is more than one driven wheel 22, the positions of multiple driven wheels 22 can be adjusted individually or in concert to adjust the tension of the cutting line 1 at multiple points. Specific adjustment methods can be achieved through mechanical structures such as lead screws and slide rails. When it is necessary to increase the tension, the driven wheel 22 is moved away from the driving wheel or other fixed support points to stretch the cutting line 1 and make it taut; when it is necessary to decrease the tension, the driven wheel 22 is moved in the opposite direction. Alternatively, the tension of the cutting line 1 can be monitored in real time, and the position of the driven wheel 22 can be adjusted accordingly to keep the cutting line 1 at a suitable tension, ensuring stable cutting operations.

[0094] This configuration allows the adjustable driven wheel 22 to precisely control the tension of the cutting line 1, preventing problems such as cutting deviation and slippage caused by slack in the cutting line 1. This results in a more accurate cutting trajectory and effectively improves cutting quality and processing precision. Furthermore, the tension of the cutting line 1 can be flexibly adjusted according to the different materials and thicknesses of the objects being cut, meeting diverse cutting needs and enabling the equipment to be widely used in various processing scenarios, thus improving its versatility and practicality.

[0095] In one or more embodiments, the number of driven wheels 22 is at least three, and the positions of the three driven wheels 22 and one driving wheel 21 are arranged in a quadrilateral cut shape.

[0096] For example, quadrilaterals that can be used as the shape of cutting line 1 include, but are not limited to, rectangles, parallelograms, squares, trapezoids, inverted trapezoids, etc.

[0097] This configuration, with at least three driven wheels 22 and one driving wheel 21 forming a quadrilateral cutting shape, ensures that the cutting line 1 maintains stable tension and shape during rotation, preventing wobbling or deviation and thus guaranteeing cutting accuracy and quality. Furthermore, the quadrilateral structure allows for a more even distribution of force across the cutting area during operation. The sides and corners of the quadrilateral better withstand and transmit cutting force, preventing excessive or insufficient localized stress, extending the service life of the cutting line 1, and resulting in a more uniform cutting effect.

[0098] Alternatively, in some other embodiments, the number of driven wheels 22 is at least two, and the positions of the two driven wheels 22 and one driving wheel 21 are arranged in a triangular cut shape.

[0099] For example, the triangles that can serve as the shape of cutting line 1 include, but are not limited to, isosceles triangles, equilateral triangles, etc.

[0100] This configuration requires only two driven wheels 22 and one drive wheel 21 for the triangular cutting shape, resulting in fewer mechanical parts and a more compact overall layout. This streamlined design significantly saves installation space, making it particularly suitable for space-constrained environments such as small processing workshops and mobile cutting equipment. Simultaneously, the compact structure reduces the overall size and weight of the equipment, facilitating transportation, installation, and maintenance. Furthermore, it reduces material and processing costs in parts procurement; and during assembly, the simplified structure reduces labor costs and assembly time. In addition, subsequent maintenance costs are lowered due to the reduced number of parts; for example, fewer wheels mean fewer lubrication, replacement, and repair needs, thus saving companies substantial funds.

[0101] In one or more embodiments, the ceramic blank wire cutting device further includes a speed detection unit, which is used to detect the speed of the ceramic blank 8 and feed the speed back to the second power unit so as to drive the cutting wire 1 to move synchronously with the ceramic blank 8 through the second power unit.

[0102] The speed detection unit can monitor the traveling speed of the ceramic blank 8 in real time through a specific detection mechanism. For example, it may use photoelectric sensors, encoders or other speed detection devices. When the ceramic blank 8 moves on the conveyor belt, these devices will generate corresponding electrical signals or pulse signals according to the movement of the ceramic blank 8.

[0103] The speed detection unit converts the detected speed information into a transmittable signal form such as an electrical signal and feeds it back to the second power unit.

[0104] The second power unit adjusts the moving speed of the cutting line 1 according to the received speed signal to keep it synchronized with the traveling speed of the ceramic blank 8. This ensures that the relative position of the cutting line 1 and the blank remains stable when cutting the ceramic blank 8, avoiding inaccurate cutting or defects caused by speed differences.

[0105] Therefore, ensuring that the cutting line 1 moves synchronously with the ceramic blank 8 enables more precise cutting, reduces cutting deviations caused by asynchronous speeds, and improves the dimensional accuracy and surface quality of the cut ceramic blank 8. This is beneficial for subsequent processing and quality control of ceramic products. Furthermore, a stable synchronous cutting process helps reduce scrap rates and improve production efficiency. Simultaneously, the improved cutting precision reduces subsequent trimming and rework, further enhancing overall production efficiency.

[0106] For example, the speed detection unit can be an encoder speed detection unit, which can be installed on the drive shaft of the conveyor belt 53 or the conveyor roller of the ceramic blank 8. As the shaft rotates, the encoder generates a series of pulse signals, each pulse corresponding to a certain displacement. By calculating the number of pulses per unit time, the traveling speed of the ceramic blank 8 can be accurately determined. This method has high detection accuracy and can adapt to different operating speeds and environmental conditions.

[0107] Alternatively, for example, the speed detection unit includes a speed detection wheel 3, which is used to measure the speed of the ceramic blank 8. The number of speed detection wheels 3 is not limited; it can be one speed detection wheel 3. Alternatively, it can be at least two speed detection wheels 3, and both speed detection wheels 3 are used to measure the speed of the ceramic blank 8.

[0108] At least two speed-detecting wheels 3 in the speed-detecting unit work closely together to measure the speed of the ceramic blank 8. When the ceramic blank 8 moves forward on the conveyor belt, its upper surface is in close contact with the circumferential surfaces of the two speed-detecting wheels 3. The friction between them causes the speed-detecting wheels 3 to rotate. An encoder is typically installed on the shaft of the speed-detecting wheel 3. As the speed-detecting wheel 3 rotates, the encoder generates a series of pulse signals, each pulse corresponding to a specific rotation angle and displacement of the speed-detecting wheel 3. By accurately calculating the number of pulses generated by the encoder per unit time, the rotational speed of the speed-detecting wheel 3 can be determined. Because the speed-detecting wheel 3 is in close contact with the ceramic blank 8 without relative sliding, the rotational speed of the speed-detecting wheel 3 is directly proportional to the traveling speed of the ceramic blank 8, thus allowing the calculation of the traveling speed of the ceramic blank 8.

[0109] Subsequently, the speed detection unit feeds back the calculated speed signal to the second power unit in the form of an electrical signal. After receiving the speed signal, the second power unit compares and analyzes it with the preset operating speed parameters of the cutting line 1, and then adjusts its own power output in real time according to the comparison results, driving the cutting line 1 to move synchronously with the ceramic blank 8 at the same speed, ensuring that the cutting line 1 remains relatively stationary with the blank during the cutting process, thereby achieving precise cutting.

[0110] This configuration, with multiple contact points between the two speed-detecting wheels 3 and the ceramic blank 8, can more comprehensively reflect the actual movement state of the ceramic blank 8, reducing speed detection errors caused by factors such as uneven blank surface and uneven force. The cooperation between the speed-detecting wheels 3 and the encoder enables high-precision pulse counting and speed calculation, providing accurate speed data for the synchronous movement of the cutting line 1 and the ceramic blank 8, significantly improving cutting accuracy and ensuring that the dimensions of the cut ceramic blank 8 better meet design requirements. Furthermore, the speed-detecting wheels 3 contact the ceramic blank 8 through friction, which is a mechanical contact detection method, eliminating the need for complex optical or electromagnetic detection environments and minimizing external interference. Even in complex environments with high dust and humidity in ceramic production workshops, it can still operate stably, ensuring the continuity and reliability of speed detection and providing strong support for the stable operation of the cutting device.

[0111] In one or more embodiments, the ceramic blank wire cutting device further includes a frame 41, a conveying unit and a second power unit disposed on the frame 41;

[0112] A first frame 42 is slidably mounted on the frame 41, a second power unit is used to drive the first frame 42 to move relative to the frame 41 along the X-axis direction, and a third power unit is mounted on the first frame 42.

[0113] The first frame 42 is slidably mounted on the second frame 43. The third power unit is used to drive the second frame 43 to move relative to the first frame 42 along the Z-axis direction. The first power unit is mounted on the second frame 43.

[0114] When this ceramic blank wire cutting device is working, each unit and component works in concert to achieve precise cutting. First, the first power unit starts, driving the cutting wire 1 to move, so that the cutting wire 1 forms a cutting area during the movement. The cutting wire 1 in this cutting area moves along the Y-axis direction to form a sawing tool.

[0115] Furthermore, during operation, the conveying unit transports the ceramic blank 8 along the X-axis. Simultaneously, the second power unit drives the first frame 42 to move relative to the frame 41 along the X-axis. Since the first power unit is mounted on the second frame 43, and the second frame 43 is connected to the first power unit, it can drive the cutting line 1 and the ceramic blank 8 to move synchronously along the X-axis, ensuring that the cutting line 1 and the ceramic blank 8 remain relatively stationary in the horizontal direction, providing a stable foundation for cutting.

[0116] When it is necessary to cut the ceramic blank 8 in the thickness direction, the third power unit comes into play. The third power unit is mounted on the first frame 42, and it drives the second frame 43 to move relative to the first frame 42 along the Z-axis, thereby driving the cutting line 1 to cut the ceramic blank 8 along the Z-axis. During the cutting process, the second power unit continuously drives the cutting line 1 to move synchronously with the ceramic blank 8, ensuring the continuity and stability of the cutting. Through the movement of the cutting line 1 along the Z-axis and its synchronous movement with the ceramic blank 8 along the X-axis, precise cutting of the ceramic blank 8 in the thickness direction is achieved.

[0117] With this setup, the first power unit drives the cutting line 1 to form a sawing tool. The conveying unit and the second power unit work together to achieve synchronous movement of the cutting line 1 and the ceramic blank 8. Combined with the cutting motion of the third power unit along the Z-axis, the multi-unit collaborative operation significantly improves the cutting efficiency compared to traditional cutting methods. It can quickly complete the cutting of the ceramic blank 8 and meet the needs of large-scale production.

[0118] Furthermore, under the precise control of each power unit, the cutting line 1 moves accurately along the X, Y, and Z axes, ensuring high cutting precision. Both the cutting position and size strictly adhere to design requirements, effectively reducing cutting errors and improving the quality of the ceramic blank 8 cutting, thus guaranteeing subsequent processing and finished product quality.

[0119] Meanwhile, the sliding arrangement of the frame 41, the first frame 42, and the second frame 43, as well as the reasonable layout of each power unit, ensures the stability of the entire cutting process. During the cutting process, the relative position of the cutting line 1 and the ceramic blank 8 remains stable, reducing cutting quality problems caused by equipment shaking or loose parts, and improving the reliability and service life of the equipment.

[0120] In one or more embodiments, a transverse slide rail 61 and a transverse slider 62 that slides in cooperation with the transverse slide rail 61 are provided between the first frame 42 and the frame body 41. This configuration, through precise mechanical cooperation, provides stable guidance for the transverse movement of the frame, reducing swaying and offset during movement. This not only ensures the trajectory accuracy of the cutting line 1 during high-frequency movement in the Y direction, further improving the consistency of cutting dimensions, but also effectively avoids abnormal wear of the cutting line 1 caused by frame swaying, extending the service life of key components of the equipment.

[0121] In one or more embodiments, a vertical slide rail 63 and a vertical slider 64 that slides in cooperation with the vertical slide rail 63 are provided between the second frame 43 and the first frame 42. This configuration allows the vertical slide rail 63 and the slider to achieve precise positioning and rapid adjustment of the second frame 43 in the vertical direction. For example, when dealing with ceramic blanks 8 of different thicknesses, the height of the second frame 43 can be easily adjusted, further improving cutting accuracy and efficiency.

[0122] In summary, the embodiments of this application achieve efficient cutting of continuously formed ceramic blanks 8 through a multi-axis linkage dynamic cutting mechanism. The specific operation process is as follows: the continuously pressed ceramic blank 8 is conveyed to the cutting device along the X direction by the conveyor belt 53. The detection wheel assembly monitors the conveying speed Vx of the ceramic blank 8 in real time and feeds the data back to the second power unit.

[0123] When the ceramic blank 8 arrives at the cutting station, the first frame 42 is driven by the second power unit. Since the second frame 43 is set on the first frame 42, the first frame 42 and the second frame 43 will move synchronously along the X direction at a speed of Vx, ensuring that the cutting line 1 and the ceramic blank 8 remain relatively stationary, thus eliminating longitudinal cutting errors.

[0124] During the cutting process, the second frame 43 descends vertically along the Z direction at a constant speed. At the same time, the first power unit drives the drive wheel to rotate continuously at high speed, causing the cutting line 1 to move at high frequency along the Y direction to form a sawing tool.

[0125] Thus, the cutting line 1 forms a composite motion trajectory in three-dimensional space: it moves synchronously with the ceramic blank 8 at a speed of Vx (X direction), achieves vertical cutting by descending at a uniform speed (Z direction), and completes the cutting by high-frequency motion (Y direction).

[0126] When the cutting line 1 descends to the Z-axis stroke corresponding to the thickness of the ceramic blank 8, a single cutting action is completed. Subsequently, the cutting line 1 can quickly rise back to the starting position along the Z-axis and quickly reset in the X-axis, waiting to execute the next cutting command. Furthermore, the cutting timing and interval can be precisely controlled based on the stroke data of the ceramic blank 8 fed back by the detection wheel assembly, realizing continuous and automated cyclic cutting.

[0127] An embodiment of this utility model also discloses a roll forming system.

[0128] In one or more embodiments, the roll forming system includes the ceramic green body wire cutting device of Embodiment 1 above, and thus has all the beneficial effects of any of the above embodiments, which will not be repeated here.

[0129] The technical means disclosed in this utility model are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of this utility model, and these improvements and modifications are also considered within the scope of protection of this utility model.

Claims

1. A wire cutting device for ceramic blanks, characterized in that, include: Cutting line; The first power unit is used to drive the movement of the cutting line; The first power unit drives the cutting line to form a cutting area during the movement, and the cutting line in the cutting area moves along the Y-axis to form a sawing tool. Furthermore, the cutting line can be made along the thickness direction of the ceramic blank.

2. The ceramic blank wire cutting device according to claim 1, characterized in that, It also includes a conveying unit and a second power unit. The conveying unit is used to convey the ceramic blank along the X-axis, and the second power unit is used to drive the cutting line to move along the X-axis. When cutting, the second power unit is used to drive the cutting line to move synchronously with the ceramic blank.

3. The ceramic blank wire cutting device according to claim 2, characterized in that, It also includes a third power unit, which is used to drive the cutting line to move along the Z-axis; When cutting, the third power unit is used to drive the cutting line to cut the ceramic blank along the Z-axis direction.

4. A wire cutting device for ceramic blanks according to any one of claims 1-3, characterized in that, The cutting line has a straight structure, and the first power unit is used to drive the cutting line itself to perform linear reciprocating motion. The first power unit includes a first power wheel and a second power wheel. The two ends of the cutting line are connected to the first power wheel and the second power wheel respectively. The first power wheel and the second power wheel can rotate synchronously in both directions to drive the cutting line to make linear reciprocating motion.

5. A wire cutting device for ceramic blanks according to any one of claims 1-3, characterized in that, The cutting line has a ring structure, and the first power unit is used to drive the cutting line to rotate in a ring. The first power unit includes a power wheel and a driven wheel, with a cutting line wound between the power wheel and the driven wheel to form a ring-shaped cutting structure.

6. The ceramic blank wire cutting device according to claim 5, characterized in that, At least one driven wheel is provided, and the position of at least one driven wheel is adjustable to tension the annular cutting line.

7. A wire cutting device for ceramic blanks according to claim 5, characterized in that, The number of driven wheels is set to at least three, and the positions of the three driven wheels and one driving wheel are arranged in a quadrilateral cut shape; Alternatively, the number of driven wheels is set to at least two, and the positions of the two driven wheels and one driving wheel are arranged in a triangular cut shape.

8. A wire cutting device for ceramic blanks according to any one of claims 1-3 and 6-7, characterized in that, It also includes a speed detection unit, which detects the speed of the ceramic blank and feeds the speed back to the second power unit so that the cutting line can be driven to move synchronously with the ceramic blank through the second power unit.

9. A wire cutting device for ceramic blanks according to claim 8, characterized in that, The speed detection unit includes at least one speed detection wheel, and the speed detection wheel is used to measure the speed of the ceramic blank.

10. A wire cutting device for ceramic blanks according to claim 3, characterized in that, It also includes a frame, a conveying unit, and a second power unit mounted on the frame; The frame is slidably equipped with a first frame, a second power unit is used to drive the first frame to move relative to the frame along the X-axis, and a third power unit is mounted on the first frame; The first frame is slidably mounted on the second frame, and the third power unit is used to drive the second frame to move relative to the first frame along the Z-axis. The first power unit is mounted on the second frame.

11. A roll forming system, characterized in that, Including a ceramic blank wire cutting device according to any one of claims 1-10.

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