A grooved wheel for wire cutting, a coating mold, and a wire cutting machine equipped with the grooved wheel.

Abstract

This invention provides a grooved wheel for wire cutting, a coating mold, and a wire cutting machine equipped with the grooved wheel. The grooved wheel includes a roller core and a coating layer. The roller core has an annular coating groove, and the coating layer is disposed within the annular coating groove. The thickness of the coating layer is less than the depth of the annular coating groove. The beneficial effects of this invention are that by setting the coating groove, the coating layer is positioned closer to the axis of the grooved wheel roller core, simplifying the structure of the coating mold and reducing its processing cost. While meeting strength requirements, the invention indirectly reduces the diameter of the grooved wheel by changing its structure, thus reducing the material usage of the roller core and polyurethane coating layer, lowering manufacturing and maintenance costs, improving cutting accuracy and equipment flexibility, reducing energy consumption, reducing cutting wire wear, and making it more suitable for high-precision cutting scenarios and the cutting of ultra-thin silicon wafers. It also reduces wire marks and improves the surface quality of the slices.

Description

Technical Field

[0001] This utility model belongs to the field of photovoltaic technology, and in particular relates to a grooved wheel for wire cutting, a coating mold, and a wire cutting machine equipped with the grooved wheel. Background Technology

[0002] The grooved roller used in the photovoltaic slicing process includes a grooved roller core. The outside of the grooved roller core is coated with a polyurethane coating, and wiring grooves are formed on the coating to support and guide the cutting lines.

[0003] The diameter of the grooved wheel directly affects cutting quality and efficiency. A larger diameter results in less curvature of the cutting line, higher stability, and better cutting quality. A larger diameter also allows for higher linear speeds, improving cutting efficiency. In current technology, the grooved wheel diameter is typically 160–200 mm. However, a larger diameter also increases equipment size and weight, leading to higher costs. It also requires a stronger support structure, increasing the complexity of equipment design. While a large-diameter grooved wheel can reduce bending stress on the cutting line and extend its lifespan, it also accelerates wear due to increased cutting speeds. At high linear speeds, a large-diameter grooved wheel may cause cutting line vibration, affecting the surface quality of the slice, resulting in line marks or increased roughness. Furthermore, a large-diameter grooved wheel requires higher driving force to maintain high-speed operation, leading to increased energy consumption.

[0004] With the trend towards thinner silicon wafers, the requirements for cutting precision are becoming higher. The thinner the silicon wafer, the more easily vibration during the cutting process can cause fragmentation or uneven thickness. A single large-diameter grooved wheel cannot meet the cutting requirements, so it is necessary to change the grooved wheel structure to solve the vibration and fragmentation problems that occur during the cutting of ultra-thin silicon wafers. Utility Model Content

[0005] To solve the above-mentioned technical problems, this utility model provides a grooved wheel for wire cutting, a coating mold, and a wire cutting machine equipped with the grooved wheel, which effectively solves the technical problem that a single large-diameter grooved wheel cannot meet the cutting requirements of ultra-thin silicon wafers and overcomes the shortcomings of the prior art.

[0006] The technical solution adopted by this utility model is: a grooved wheel for wire cutting, including a roller core, an annular coating groove is provided on the roller core, a coating layer is provided in the annular coating groove, and the thickness of the coating layer is less than the depth of the annular coating groove.

[0007] Furthermore, the ratio of the thickness of the coating layer to the depth of the annular coating groove is 1:1.5 to 1:4.

[0008] Furthermore, the outer wall diameter of the coating layer is set to 130-140 mm, and the bottom diameter of the annular coating groove is 115-125 mm.

[0009] Furthermore, the roller core is also provided with a slot, which is used to connect the rotating shaft of the wire cutting machine; the slot is arranged along the axis of the roller core, and the diameter of the slot is 55-65mm.

[0010] Furthermore, the slot has tapered holes at both ends for connecting to the rotating shaft of the wire cutting machine, and the angle of the tapered holes is set to 19-21°.

[0011] Furthermore, a wiring groove is formed on the coating layer, and the thickness of the coating layer is greater than the depth of the wiring groove, wherein the thickness of the coating layer is 25 to 50 times the depth of the wiring groove.

[0012] Furthermore, along the axis of the roller core, the wiring groove includes a first segment, a second segment, and a third segment; the average groove spacing between adjacent wiring grooves in the first segment is greater than the average groove spacing between adjacent wiring grooves in the second segment; the average groove spacing between adjacent wiring grooves in the third segment is greater than the average groove spacing between adjacent wiring grooves in the second segment.

[0013] A coating mold, which is clamped on the roller core of a wire cutting grooved wheel as described above, for casting the coating layer in the annular coating groove.

[0014] Furthermore, it includes a mold body, on which clamping pins are provided.

[0015] A wire cutting machine is provided with a grooved wheel for wire cutting as described above.

[0016] The advantages and positive effects of this utility model are as follows: By setting an annular coating groove, the coating layer is placed inside the annular coating groove, thereby making the coating layer closer to the axis of the grooved wheel core. This simplifies the structure of the coating mold and reduces the processing cost of the coating mold. Under the premise of meeting the strength requirements, the diameter of the grooved wheel is indirectly reduced by changing the grooved wheel structure, which reduces the amount of material used in the grooved wheel core and polyurethane coating layer, thereby reducing manufacturing and maintenance costs. At the same time, the small-diameter grooved wheel improves cutting accuracy, increases equipment flexibility, reduces energy consumption, reduces cutting line wear, and reduces enclosure costs. It is more suitable for high-precision cutting scenarios, adapts to industry development trends, and is more suitable for cutting ultra-thin silicon wafers, reducing line marks and improving the surface quality of the slices. Attached Figure Description

[0017] The above and other objects, features, and advantages of this utility model will become more apparent from the more detailed description of the embodiments thereof in conjunction with the accompanying drawings. The drawings are provided to further illustrate the embodiments of this utility model and form part of the specification. They are used together with the embodiments of this utility model to explain the utility model and do not constitute a limitation thereof. In the drawings, the same reference numerals generally represent the same parts or steps.

[0018] Figure 1 This is a schematic diagram of the structure of a grooved wheel for wire cutting according to an embodiment of the present invention.

[0019] Figure 2 This is a front view of a coating mold according to an embodiment of the present invention.

[0020] Figure 3 This is a side view of a coating mold according to an embodiment of the present invention.

[0021] Figure 4 This is a schematic diagram showing the maximum bending stress and maximum deformation of a grooved wheel for wire cutting according to an embodiment of this utility model.

[0022] Figure 5 This is a schematic diagram showing the maximum stress and maximum deformation of the end cone surface of a grooved wheel for wire cutting according to an embodiment of this utility model.

[0023] In the picture:

[0024] 10. Roller core; 11. Coating layer; 12. Annular coating groove

[0025] 13. Boss 14. Tapered hole 15. Slot

[0026] 20. Mold body 21. Clamping pin Detailed Implementation

[0027] This utility model provides a grooved wheel for wire cutting, a coating mold, and a wire cutting machine equipped with the grooved wheel. The embodiments of this utility model will be described below with reference to the accompanying drawings.

[0028] In the description of the embodiments of this utility model, it should be understood that the terms "top," "bottom," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and 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, and therefore should not be construed as a limitation of this utility model. In the description of this utility model, it should be noted that unless otherwise expressly specified and limited, the terms "set" and "connected" should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral connection; it can refer to a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication of two elements. Those skilled in the art can understand the specific meaning of the above terms in this utility model through specific circumstances.

[0029] like Figure 1As shown in the figure, an embodiment of the present invention discloses a grooved wheel for wire cutting, comprising a roller core 10 and a coating layer 11. The roller core 10 has an annular coating groove 12, within which the coating layer 11 is disposed. The annular coating groove 12 is located in the middle of the side wall of the roller core 10, and symmetrical bosses 13 are formed at both ends of the roller core 10. The length of the annular coating groove 12 is set according to the length of the silicon rod. The thickness of the coating layer 11 is less than the depth of the annular coating groove 12. To match existing machine bodies, the diameter of the bosses 13 remains unchanged and is the same as the diameter of the original grooved wheel roller core. By opening the annular coating groove 12 on the roller core 10, the coating layer 11 is disposed within the annular coating groove 12. Compared to the prior art where the coating layer is directly disposed on the outer wall of the grooved wheel roller core, this method places the coating layer closer to the axis of the roller core 10. By changing the structure of the grooved wheel, the diameter of the grooved wheel is indirectly reduced, thereby improving the cutting accuracy and enabling the cutting of ultra-thin silicon wafers. Meanwhile, since the boss 13 is provided, when casting the coating layer 11, it is only necessary to clamp the coating mold on the outside of the roller core 10. There is no need to set a flange at the end of the coating mold to axially position the coating layer 11, which simplifies the structure of the coating mold.

[0030] Preferably, the ratio of the thickness of the coating layer to the depth of the annular coating groove is 1:1.5 to 1:4.

[0031] Specifically, the outer wall diameter φ3 of the coating layer is set to 130-140mm, and the bottom wall diameter φ1 of the annular coating tank is 115-125mm.

[0032] Specifically, the roller core 10 is also provided with slots 15, which are arranged along the axis of the roller core, and the diameter φ4 of the slots is 55-65mm. Tapered holes 14 are provided at both ends of the slots 15 of the roller core 10. By providing the tapered holes 14, the two ends of the roller core 10 are connected to the rotating shaft of the wire cutting machine through tapered sleeves, thereby driving the grooved wheel to rotate. The angle of the tapered holes 14 is set to 19-21°.

[0033] The ratio of the outer wall diameter of the coating layer to the bottom diameter of the annular coating groove and the diameter of the slot hole in the grooved roller core is set to φ3:φ1:φ4 = (130~140):(115~125):(55~65). Strength and stiffness simulation of the grooved roller is then performed. Figure 4 The maximum stress and maximum deformation of the grooved wheel during bending are as follows: when the roller core is made of 150 steel, the maximum stress is 17 MPa and the maximum deformation is 94.4 μm; when the roller core is made of 120 steel, the maximum stress is 22 MPa and the maximum deformation is 185 μm. The grooved wheel meets the usage requirements during high-speed operation. Figure 5The maximum stress and maximum deformation of the tapered surface at the end of the grooved wheel are as follows: When the roller core is made of 150 steel, the maximum stress on the tapered surface is 82 MPa with a safety factor of 9.57, and the maximum deformation is 30.83 μm. When the roller core is made of 120 steel, the maximum stress on the tapered surface is 99.77 MPa with a safety factor of 7.8, and the maximum deformation is 46.89 μm. With the grooved wheel clamped at both ends on the wire cutting machine, no expanding cracks will occur on the tapered surface. Therefore, it can be concluded that the grooved wheel for wire cutting meets the strength requirements.

[0034] Specifically, the coating layer 11 has multiple wiring grooves for supporting and guiding the cutting wire. The wiring grooves are typically V-shaped. To prevent the cutting wire from rigidly contacting the roller core 10 at the bottom of the wiring groove, the thickness of the coating layer 11 must be greater than the depth of the wiring groove. When the wiring groove is severely worn, it needs to be re-established on the coating layer. To avoid the bottom of the wiring groove being too close to the steel surface, causing the hardness to reflect the steel surface hardness rather than the performance of the coating layer 11, resulting in abnormal cutting, the coating layer thickness is preferably 25 to 50 times the depth of the wiring groove.

[0035] Optionally, along the axis of the roller core, the wiring groove includes a first section, a second section, and a third section. The average groove spacing between adjacent wiring grooves in the first section is greater than that in the second section, and the average groove spacing between adjacent wiring grooves in the third section is greater than that in the second section. That is, the groove spacing between the wiring grooves at both ends of the grooved wheel is greater than the groove spacing in the middle. Because the tension force in the middle of the grooved wheel is less than that at its ends during cutting, the groove spacing in the middle of the grooved wheel becomes smaller, allowing for more wiring grooves to be opened in the middle of the grooved wheel. This results in more cutting wires being wound around the middle of the grooved wheel, reducing the deformation of the grooved wheel caused by long-term uneven stress between the ends and the middle.

[0036] Specifically, the end face of the roller core 10 has evenly distributed dynamic balancing holes. During the wire cutting process, the coating layer 11 will be worn away, and the high-speed motor drives the grooved wheel to cut, causing deviations in the dynamic balance quality at both ends, affecting normal cutting. Therefore, regular dynamic balancing checks are necessary to minimize the imbalance during the high-speed operation of the grooved wheel. A dynamic balancing instrument is typically used for testing, and lead wire is placed inside the dynamic balancing holes for dynamic balancing correction. The dynamic balancing holes are not shown in the figure.

[0037] A coating mold, such as Figure 2 and Figure 3As shown, the roller core 10, clamped on the grooved wheel for wire cutting as described above, is used to pour the coating layer 11 into the annular coating groove 12. It includes a mold body 20, on which clamping pins 21 are provided. The mold body 20 is cylindrical and can be fitted onto the outside of the roller core 10. To fix the mold body 20 onto the roller core 10, an opening is provided on one side of the mold body 20, and the clamping pins 21 are connected to the opening. Tightening the clamping pins 21 can fix the mold body 20 onto the roller core 10, clamping the roller core 10. The bosses 13 at both ends contact the inner wall of the mold body 20 to facilitate the pouring of the coating layer 11 into the annular coating groove 12. The coating layer 11 is made of polyurethane.

[0038] A wire cutting machine is provided with a grooved wheel for wire cutting as described above.

[0039] Example 1: A grooved roller for wire cutting includes a roller core 10 and a coating layer 11. The roller core 10 has an annular coating groove 12, and the coating layer 11 is disposed within the annular coating groove 12. The annular coating groove 12 is located in the middle of the side wall of the roller core 10, and symmetrical bosses 13 are formed at both ends of the roller core 10. The length of the silicon rod is typically 910 mm, the length of the annular coating groove 12 is set to L1 = 920 mm, and the total length of the roller core 10 is L2 = 960 mm. The bottom wall diameter of the annular coating groove is set to φ1 = 115 mm, and the diameter of the bosses 13 at both ends is set to φ2 = 154 mm. The inner diameter of the coating layer 11 is φ1 = 115 mm, and the outer diameter is φ3 = 130 mm. The depth of the annular coating groove is 19.5 mm, and the thickness of the coating layer is 7.5 mm. The depth of the wiring groove on the coating layer 11 is set to 0.2 mm, and tapered holes 14 are provided at both ends of the roller core 10, with slots 15 between the tapered holes 14. The diameter of the slot 15 is set to φ4 = 55mm, and the angle α of the tapered hole 14 is set to 20°. The end face of the roller core 10 has evenly distributed dynamic balancing holes. Along the roller core axis, the wiring groove includes a first section, a second section, and a third section. The average groove spacing between adjacent wiring grooves in the first section is greater than the average groove spacing between adjacent wiring grooves in the second section, and the average groove spacing between adjacent wiring grooves in the third section is greater than the average groove spacing between adjacent wiring grooves in the second section.

[0040] Example 2: A grooved roller for wire cutting includes a roller core 10 and a coating layer 11. The roller core 10 has an annular coating groove 12, and the coating layer 11 is disposed within the annular coating groove 12. The annular coating groove 12 is located in the middle of the side wall of the roller core 10, and symmetrical bosses 13 are formed at both ends of the roller core 10. The length of the silicon rod is typically 910 mm, the length of the annular coating groove 12 is set to L1 = 920 mm, and the total length of the roller core 10 is L2 = 960 mm. The bottom wall diameter of the annular coating groove is set to φ1 = 120 mm, and the diameter of the bosses 13 at both ends is set to φ2 = 154 mm. The inner diameter of the coating layer 11 is φ1 = 120 mm, and the outer diameter is φ3 = 135 mm. The depth of the annular coating groove is 17 mm, and the thickness of the coating layer is 7.5 mm. The depth of the wiring groove on the coating layer 11 is set to 0.2 mm. Tapered holes 14 are provided at both ends of the roller core 10, and slots 15 are provided between the tapered holes 14. The diameter of the slot 15 is set to φ4 = 60mm, and the angle α of the tapered hole 14 is set to 20°. The end face of the roller core 10 has evenly distributed dynamic balancing holes. Along the roller core axis, the wiring groove includes a first section, a second section, and a third section. The average groove spacing between adjacent wiring grooves in the first section is greater than the average groove spacing between adjacent wiring grooves in the second section, and the average groove spacing between adjacent wiring grooves in the third section is greater than the average groove spacing between adjacent wiring grooves in the second section.

[0041] Example 3: A grooved roller for wire cutting includes a roller core 10 and a coating layer 11. The roller core 10 has an annular coating groove 12, and the coating layer 11 is disposed within the annular coating groove 12. The annular coating groove 12 is located in the middle of the side wall of the roller core 10, and symmetrical bosses 13 are formed at both ends of the roller core 10. The length of the silicon rod is typically 910 mm, the length of the annular coating groove 12 is set to L1 = 920 mm, and the total length of the roller core 10 is L2 = 960 mm. The bottom wall diameter of the annular coating groove is set to φ1 = 125 mm, and the diameter of the bosses 13 at both ends is set to φ2 = 154 mm. The inner diameter of the coating layer 11 is φ1 = 125 mm, and the outer diameter is φ3 = 140 mm. The depth of the annular coating groove is 14.5 mm, and the thickness of the coating layer is 7.5 mm. The depth of the wiring groove on the coating layer 11 is set to 0.2 mm. Tapered holes 14 are provided at both ends of the roller core 10, and slots 15 are provided between the tapered holes 14. The diameter of the slot 15 is set to φ4 = 60mm, and the angle α of the tapered hole 14 is set to 20°. The end face of the roller core 10 has evenly distributed dynamic balancing holes. Along the roller core axis, the wiring groove includes a first section, a second section, and a third section. The average groove spacing between adjacent wiring grooves in the first section is greater than the average groove spacing between adjacent wiring grooves in the second section, and the average groove spacing between adjacent wiring grooves in the third section is greater than the average groove spacing between adjacent wiring grooves in the second section.

[0042] A coating mold, clamped on a roller core 10 as described above, is used to pour a coating layer 11 into an annular coating groove 12. The mold includes a mold body 20, on which clamping pins 21 are provided. The mold body 20 is a stainless steel cylinder with a total length of 960 mm, a wall thickness of 1.5 mm, and an inner diameter of 154.5 mm. It can be fitted onto the outside of the roller core 10. An opening is provided on one side of the mold body 20, and the clamping pins 21 are connected to the opening. Tightening the clamping pins 21 can fix the mold body 20 onto the roller core 10, clamping the roller core 10. The bosses 13 at both ends contact the inner wall of the mold body 20 to facilitate the pouring of the coating layer 11 into the annular coating groove 12. The coating layer 11 is made of polyurethane.

[0043] The advantages and positive effects of this utility model are:

[0044] 1. By setting a coating groove, the coating layer is placed inside the coating groove, thereby bringing the coating layer closer to the axis of the grooved roller core. By changing the grooved roller structure, the diameter of the grooved roller is indirectly reduced, simplifying the structure of the coating mold and reducing the processing cost of the coating mold.

[0045] 2. Reduced material costs: While meeting strength requirements, the diameter of the grooved wheel was reduced, which decreased the amount of material used in the grooved wheel core and polyurethane coating, thus reducing manufacturing costs. At the same time, the smaller diameter grooved wheel is lighter, reducing equipment load and lowering overall equipment costs.

[0046] 3. Improved cutting accuracy: Small-diameter grooved wheels can reduce the bowing effect of the cutting wire during high-speed operation, thereby improving cutting accuracy. They are more suitable for cutting ultra-thin silicon wafers, reducing wire marks and improving the surface quality of the slices.

[0047] 4. Improved equipment flexibility: Small-diameter grooved wheels occupy less space, making the equipment structure more compact and easier to install and operate in limited spaces, thus improving the equipment's versatility and flexibility.

[0048] 5. Reduced energy consumption: Small-diameter Geneva wheels require less driving force during operation, thus reducing equipment energy consumption. Due to their lower inertia, small-diameter Geneva wheels can accelerate and decelerate more quickly, improving equipment response speed.

[0049] 6. Reduced cutting wire wear: Although small-diameter grooved wheels may increase the bending frequency of the cutting wire, they can reduce the stress of a single bend during low- or medium-speed cutting, thereby extending the service life of the cutting wire. The small-diameter design can better control the tension distribution of the cutting wire and reduce local wear.

[0050] 7. Suitable for high-precision cutting scenarios: In scenarios requiring high-precision cutting (such as laboratory or special material cutting), small-diameter grooved wheels can provide higher stability and accuracy. The small-diameter design is more suitable for cutting tasks with complex shapes or small dimensions.

[0051] 8. Reduced maintenance costs: Small-diameter grooved wheels are lightweight and compact, making replacement and maintenance easier. Due to their simple structure, small-diameter grooved wheels have a relatively low failure rate, reducing downtime and maintenance costs.

[0052] 9. Adapting to industry development trends: As the photovoltaic industry places increasingly higher demands on thinner silicon wafers, small-diameter grooved wheels can better meet the cutting needs of ultra-thin silicon wafers. When cutting new materials (such as silicon carbide), the small-diameter design can provide higher precision and adaptability.

[0053] The embodiments of this disclosure have been described in detail above with reference to the accompanying drawings. It should be noted that implementations not illustrated or described in the drawings or the main text of the specification are forms known to those skilled in the art and have not been described in detail. Furthermore, the definitions of the various components described above are not limited to the specific structures, shapes, or methods mentioned in the embodiments, and those skilled in the art can easily modify or substitute them.

[0054] The embodiments of this utility model have been described in detail above, but the content described is only a preferred embodiment of this utility model and should not be considered as limiting the scope of implementation of this utility model. All equivalent changes and improvements made in accordance with the claims of this utility model should still fall within the patent coverage of this utility model.

Claims

1. A slot wheel for thread cutting, characterized in that: It includes a roller core, the roller core having an annular coating groove along its outer periphery, the annular coating groove having a coating layer inside the annular coating groove, the thickness of the coating layer being less than the depth of the annular coating groove.

2. A slot wheel according to claim 1, wherein: The ratio of the thickness of the coating layer to the depth of the annular coating groove is 1:1.5 to 1:

4.

3. A slot wheel according to claim 2, wherein: The outer wall diameter of the coating layer is set to 130-140 mm, and the bottom diameter of the annular coating groove is 115-125 mm.

4. A slot wheel according to claim 1, wherein: The roller core is also provided with a slot for connecting the shaft of the wire cutter; the slot is arranged along the axis of the roller core and the diameter of the slot is 55-65mm.

5. A slot wheel according to claim 4, wherein: The slot has tapered holes at both ends; the angle of the tapered holes is 19 to 21°.

6. A slot wheel according to any one of claims 1-5, characterized in that: The coating layer has wiring grooves, and the thickness of the coating layer is 25 to 50 times the depth of the wiring grooves.

7. A slot wheel according to claim 6, wherein: Along the axis of the roller core, the wiring groove includes a first section, a second section, and a third section; The average spacing between adjacent wiring slots in the first segment is greater than the average spacing between adjacent wiring slots in the second segment. The average spacing between adjacent wiring slots in the third segment is greater than the average spacing between adjacent wiring slots in the second segment.

8. A coating die characterized by: The coating mold is clamped on the roller core of the grooved wheel for wire cutting as described in any one of claims 1-7, and the coating layer is poured into the annular coating groove.

9. A coating mold according to claim 8, characterized in that: It includes a mold body, on which clamping pins are provided.

10. A wire cutting machine characterized by: The device is equipped with a grooved wheel for wire cutting as described in any one of claims 1-7.

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