Rope saw cutting monitoring system and rope saw cutting device

Abstract

The utility model discloses a kind of rope saw cutting monitoring system and rope saw cutting device, the system includes for monitoring rope tension tension sensor, for monitoring device vibration acceleration sensor, for monitoring driving motor load load sensor, for monitoring device feed displacement displacement sensor, for monitoring cutting temperature temperature sensor and for monitoring cooling water flow rate flow sensor;Tension sensor is installed on the tensioning wheel of rope;Acceleration sensor is arranged at rack or rope protection shell;Load sensor is arranged on the loop of driving motor and can monitor the current of driving motor, or, it is arranged on the main shaft of driving motor and can monitor the torque of driving motor;Displacement sensor cooperates with feed mechanism and can monitor the displacement of rack;Temperature sensor is arranged near cut joint or rope;Flow sensor is arranged on cooling water pipeline.The system can be accurately grasped by operator Device state, cutting temperature and cooling water flow rate can also be monitored.

Description

Technical Field

[0001] This utility model belongs to the field of cutting equipment, specifically relating to a wire saw cutting monitoring system and a wire saw cutting device. Background Technology

[0002] Wire saw cutting technology is widely used in the demolition of reinforced concrete components such as foundations, tie beams, and piers. A typical wire saw cutting device includes a closed rope (usually diamond bead steel rope) with cutting elements along the line, a drive wheel that drives the rope, a drive motor that drives the drive wheel, a tension wheel that tensions the rope, a guide wheel that guides the rope, and a feed mechanism that feeds the device. Before operation, the rope is placed on the component to be cut and kept taut. During operation, the drive motor drives the rope to rotate at high speed to grind and cut the component, while the feed mechanism feeds the device to gradually increase the cutting depth until the cut is complete.

[0003] Compared with traditional blasting or mechanical chiseling, wire sawing has the advantages of smooth cuts, low noise, and low vibration. It has significant advantages in controlling the damage range, maintaining the stability of the superstructure, and reducing secondary damage. Therefore, it has gradually become the mainstream method for bridge demolition and partial reconstruction.

[0004] However, traditional wire saw cutting devices suffer from several drawbacks in practical use due to the lack of real-time monitoring: 1) Operators rely on experience to adjust rope tension, which can easily lead to breakage when the tension is too high or slippage when it is too low, affecting cutting efficiency and creating safety hazards; 2) When the equipment experiences motor overload, abnormal cutting resistance, or rope jamming, operators often fail to recognize these issues in time, only noticing them after the malfunction becomes severe or the machine is shut down; 3) Operators rely on experience to control the cutting progress, making it difficult to maintain consistent cutting speeds at both ends of the wire saw, often resulting in skewed cut surfaces or even structural misalignment; 4) Traditional wire saw cutting devices still use a fixed-flow water supply for cooling, which cannot be dynamically adjusted according to the cutting load, leading to water waste and increased slurry discharge, which does not meet the requirements of green construction. Utility Model Content

[0005] The purpose of this utility model is to provide a wire saw cutting monitoring system and a wire saw cutting device including the above system. The system allows operators to accurately grasp the status of the device, avoids potential operational hazards, and can also monitor the cutting temperature and cooling water flow rate, making it convenient to adjust the cooling water flow rate and avoid water waste.

[0006] The technical solution adopted in this utility model is: A wire saw cutting monitoring system includes a tension sensor for monitoring rope tension, an acceleration sensor for monitoring device vibration, a load sensor for monitoring drive motor load, a displacement sensor for monitoring device feed displacement, a temperature sensor for monitoring cutting temperature, and a flow sensor for monitoring cooling water flow rate. The tension sensor is mounted on the rope tensioning pulley; the acceleration sensor is located on the frame or rope protective housing; the load sensor is located in the drive motor circuit and monitors the drive motor current, or located on the drive motor spindle and monitors the drive motor torque; the displacement sensor cooperates with the feed mechanism and monitors the frame displacement; the temperature sensor is located near the kerf or rope; and the flow sensor is located on the cooling water pipe.

[0007] Preferably, the tension sensor adopts a load pin structure and is installed at the axle pin position of the tensioning wheel to replace the original axle pin.

[0008] Preferably, the accelerometer is a triaxial sensor with a protective cover installed on its outer side.

[0009] Preferably, the displacement sensor is a magnetic grating linear displacement sensor.

[0010] Preferably, the temperature sensor is a combination of an infrared thermometer and a thermocouple.

[0011] Preferably, the flow sensor is a combination of an electromagnetic flow meter and a PT100 thermometer.

[0012] Preferably, the signal lines of each sensor are shielded cables and covered with protective sleeves, and the interfaces of each sensor all meet or exceed the IP67 protection level.

[0013] Preferably, it further includes a data acquisition and processing unit for collecting and processing various monitoring data, a display module for displaying various monitoring data, and an alarm module for alarming abnormalities; the data acquisition and processing unit includes a data acquisition box, a signal conditioning circuit, a data processing module, and a control interface, the signal lines of each sensor are respectively connected to the data acquisition box, the data acquisition box, the signal conditioning circuit, and the data processing module are electrically connected in sequence, the data processing module is electrically connected to the control interface, the display module, and the alarm module, and the control interface is electrically connected to the drive motor, the feeding mechanism, and the flow control component of the cooling water.

[0014] Preferably, the data acquisition and processing unit further includes a storage module for data storage and uploading, and an interface for data communication with the management platform.

[0015] A wire saw cutting device includes a device body and the aforementioned wire saw cutting monitoring system. The device body includes a closed rope with cutting elements along the line, a drive wheel that can drive the rope, a drive motor for driving the drive wheel, a tension wheel for tensioning the rope, a guide wheel for guiding the rope, a feed mechanism for driving the device to feed, and a cooling water mechanism for cooling. The cooling water mechanism includes cooling water pipes and flow control components.

[0016] The beneficial effects of this utility model are: The system deploys appropriate sensors at key locations to monitor rope tension, device vibration, drive motor load, and device feed displacement. Operators can accurately grasp the device's status and promptly detect and address issues such as abnormal rope tension, excessive vibration amplitude, sudden increases in motor load, and asynchronous feed, thus avoiding potential operational hazards. The system can also monitor cutting temperature and cooling water flow, allowing operators to adjust the cooling water flow based on the cutting temperature and avoid water waste. The system is easy to install and remove; it can be installed with new equipment during production or added to existing equipment during retrofitting, making it worthy of widespread adoption.

[0017] This system can achieve automated control using data acquisition and processing units, and also has data display and abnormal alarm functions. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the wire saw cutting device in an embodiment of this utility model.

[0019] Figure 2 This is a schematic diagram illustrating the working principle of the rope in this embodiment of the utility model.

[0020] In the diagram: 1-Screw; 2-Slide rail; 3-Base plate; 4-Displacement sensor; 5-Display module; 6-Tension wheel; 7-Frame; 8-Acceleration sensor; 9-Drive motor; 10-Drive wheel; 11-Rope; 12-Temperature sensor; 13-Pier column; 14-Pile cap; 15-Load sensor; 16-Cooling water pipe; 17-Guide wheel; 18-Tension sensor; 19-Adjusting bolt; 20-Rope adjusting section; 21-Flow sensor; 22-Flow control component; 23-Alarm module. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0022] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0023] The features and performance of this application will be further described in detail below with reference to the embodiments.

[0024] Example 1 This embodiment discloses a wire saw cutting monitoring system, such as Figure 1 As shown, the device includes a tension sensor 18, an acceleration sensor 8, a load sensor 15, a displacement sensor 4, a temperature sensor 12, and a flow sensor 21. Specifically: the tension sensor 18 monitors the tension of the rope 11 and is mounted on the tensioning pulley 6 of the rope 11; the acceleration sensor 8 monitors device vibration and is located on the frame 7 or the protective shell of the rope 11; the load sensor 15 monitors the load of the drive motor 9 and is located in the circuit of the drive motor 9, monitoring the current of the drive motor 9, or it is located on the main shaft of the drive motor 9, monitoring the torque of the drive motor 9; the displacement sensor 4 monitors the feed displacement of the device and cooperates with the feed mechanism to monitor the displacement of the frame 7; the temperature sensor 12 monitors the cutting temperature and is located near the cutting kerf or the rope 11; and the flow sensor 21 monitors the cooling water flow rate and is located on the cooling water pipe 16.

[0025] The system deploys appropriate sensors at key locations to monitor the tension of rope 11, device vibration, drive motor 9 load, and device feed displacement. Operators can accurately grasp the device status and promptly detect and address issues such as abnormal rope 11 tension, excessive vibration amplitude, sudden increase in motor load, and asynchronous feed, thus avoiding potential operational hazards.

[0026] The system can also monitor cutting temperature and cooling water flow, allowing operators to adjust the cooling water flow according to the cutting temperature and avoid water waste.

[0027] The system is easy to install and remove; it can be installed with new equipment during production or added to old equipment during retrofitting, making it worthy of widespread adoption.

[0028] In this embodiment, preferably, the tension sensor 18 adopts a load pin structure and is installed on the shaft pin position of the tensioning wheel 6 to replace the original shaft pin, which is easy to install and does not damage the main structure.

[0029] In this embodiment, preferably, the acceleration sensor 8 is a triaxial sensor, and a protective cover is installed on its outside to avoid slurry corrosion. The acceleration sensor 8 can be installed by clamping or magnetic fixation.

[0030] In this embodiment, preferably, the displacement sensor 4 is a magnetic grating linear displacement sensor to adapt to dusty and high-humidity environments. The displacement sensor 4 can be installed on the frame 7 by clamping or magnetic attraction.

[0031] In this embodiment, preferably, the temperature sensor 12 is a combination of an infrared thermometer and a thermocouple, which can perform non-contact temperature measurement and can also be calibrated at the contact measurement point, taking into account both non-contact and contact accuracy. The infrared thermometer and the thermocouple can be installed by means of clamp fixation or magnetic fixation.

[0032] In this embodiment, preferably, the flow sensor 21 is a combination of an electromagnetic flow meter and a PT100 thermometer to ensure measurement accuracy and stability.

[0033] In this embodiment, preferably, the signal lines of each sensor are shielded cables and covered with protective sleeves, and the interfaces of each sensor all reach an IP67 protection level or above to adapt to the humid and dusty environment inside the tunnel.

[0034] To achieve automated control and also provide data display and alarm functions, in this embodiment, preferably, the system further includes a data acquisition and processing unit for collecting and processing various monitoring data, a display module 5 for displaying various monitoring data, and an alarm module 23 for alarming abnormalities. The data acquisition and processing unit includes a data acquisition box, a signal conditioning circuit, a data processing module, and a control interface. The signal lines of each sensor are connected to the data acquisition box. The data acquisition box, the signal conditioning circuit, and the data processing module are electrically connected in sequence. The data processing module is electrically connected to the control interface, the display module 5, and the alarm module 23. The control interface is electrically connected to the drive motor 9, the feeding mechanism, and the flow control component 22 of the cooling water.

[0035] During operation, the signals output by each sensor are uniformly connected to the data acquisition box. After filtering, amplification, and analog-to-digital conversion by the signal conditioning circuit, they enter the data processing module. The data processing module performs real-time calculations and analysis on the signals. The display module 5 displays real-time monitoring data such as tension, vibration, load, displacement, cutting temperature, and cooling water flow. When the data processing module detects states such as increased / exceeded tension limits, increased / exceeded vibration limits, increased / exceeded load limits, asynchronous feed, or excessive cutting temperature, it generates alarm or control commands, thereby achieving intelligent control of the entire process. When the data processing module detects that the monitored data has increased / exceeded the limit, it sends an alarm command to the alarm module 23, and the alarm module 23 then issues an audible and visual alarm. When the data processing module detects an increase in tension, vibration, or load, it sends a control command to the drive motor 9, which then controls the drive motor 9 to slow down the cutting speed. When the data processing module detects that the tension, vibration, load or cutting temperature exceeds the limit, it sends control commands to the drive motor 9, the feed mechanism and the flow control component 22, and the drive motor 9, the feed mechanism and the flow control component 22 stop working and trigger the shutdown protection. When the data processing module detects that the feed rate is out of sync, it sends a control command to the feeding mechanism, which then adjusts the feed speed until the feed rate is synchronized. The data processing module dynamically controls the flow control component 22 based on the cutting temperature, increasing the cooling water flow when the cutting temperature rises and decreasing the cooling water flow when the cutting temperature falls.

[0036] Furthermore, preferably, the data acquisition and processing unit also includes a storage module for data storage and uploading, and an interface for data communication with a management platform (e.g., a smart construction site platform). The storage module can permanently store monitoring data during the operation process and upload it to the management platform through the interface, forming a traceable construction data archive.

[0037] In this embodiment, the data processing module adopts an industrial control computer or an edge computing module, and the display module 5 adopts an industrial display screen of 7 inches or larger and has a Modbus or Ethernet communication interface.

[0038] Example 2 This embodiment discloses a wire saw cutting device, including a device body and the wire saw cutting monitoring system described in Embodiment 1 above, such as... Figure 1 and Figure 2 As shown, the main body of the device includes a closed rope 11 with cutting elements along the line, a drive wheel 10 that can drive the rope 11, a drive motor 9 for driving the drive wheel 10, a tension wheel 6 for tensioning the rope 11, a guide wheel 17 for guiding the rope 11, a feed mechanism for driving the device to feed, and a cooling water mechanism for cooling. The cooling water mechanism includes a cooling water pipe 16 and a flow control component 22.

[0039] In this embodiment, as Figure 1 As shown, the feeding mechanism includes a base plate 3 with a slide rail 2, a frame 7 supported on the base plate 3 and cooperating with the slide rail 2, a lead screw 1 for moving the frame 7 along the slide rail 2, and a feed motor for driving the lead screw 1.

[0040] In this embodiment, as Figure 1 As shown, the tension wheel 6 adjusts the length of the rope adjustment section 20 by adjusting the adjusting bolt 19, thereby adjusting the tension.

[0041] In this embodiment, the cooling water pipe 16 is covered with insulation cotton to ensure stable water temperature under extreme climate conditions and prevent the pipe from freezing or cooling efficiency from decreasing.

[0042] In this embodiment, the rope 11 is preferably a diamond beaded rope.

[0043] like Figure 1 As shown, the device can cut reinforced concrete foundations 14 and piers 13, and of course it can also cut other reinforced concrete components (such as tie beams), steel components, etc.

[0044] The embodiments described above are some, but not all, of the embodiments of this application. The detailed description of the embodiments of this application is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

Claims

1. A wire saw cutting monitoring system, characterized in that: It includes a tension sensor for monitoring rope tension, an acceleration sensor for monitoring device vibration, a load sensor for monitoring drive motor load, a displacement sensor for monitoring device feed displacement, a temperature sensor for monitoring cutting temperature, and a flow sensor for monitoring cooling water flow rate; the tension sensor is mounted on the rope tensioning pulley; The acceleration sensor is located on the frame or rope protective housing; The load sensor is located in the circuit of the drive motor and can monitor the current of the drive motor, or it is located on the main shaft of the drive motor and can monitor the torque of the drive motor; the displacement sensor works with the feed mechanism and can monitor the displacement of the frame; the temperature sensor is located near the slit or rope; the flow sensor is located on the cooling water pipe.

2. The wire saw cutting monitoring system as described in claim 1, characterized in that: The tension sensor adopts a load pin structure and is installed at the shaft pin position of the tensioning wheel to replace the original shaft pin.

3. The wire saw cutting monitoring system as described in claim 1, characterized in that: The accelerometer is a triaxial sensor with a protective cover installed on its outside.

4. The wire saw cutting monitoring system as described in claim 1, characterized in that: The displacement sensor is a magnetic grating linear displacement sensor.

5. The wire saw cutting monitoring system as described in claim 1, characterized in that: The temperature sensor uses a combination of an infrared thermometer and a thermocouple.

6. The wire saw cutting monitoring system as described in claim 1, characterized in that: The flow sensor uses a combination of an electromagnetic flow meter and a PT100 thermometer.

7. The wire saw cutting monitoring system as described in claim 1, characterized in that: The signal lines of each sensor are shielded cables and covered with protective sleeves, and the interfaces of each sensor all meet or exceed the IP67 protection level.

8. The wire saw cutting monitoring system as described in any one of claims 1 to 7, characterized in that: It also includes a data acquisition and processing unit for collecting and processing various monitoring data, a display module for displaying various monitoring data, and an alarm module for alarming abnormalities. The data acquisition and processing unit includes a data acquisition box, a signal conditioning circuit, a data processing module, and a control interface. The signal lines of each sensor are connected to the data acquisition box. The data acquisition box, the signal conditioning circuit, and the data processing module are electrically connected in sequence. The data processing module is electrically connected to the control interface, the display module, and the alarm module. The control interface is electrically connected to the drive motor, the feeding mechanism, and the flow control components of the cooling water.

9. The wire saw cutting monitoring system as described in claim 8, characterized in that: The data acquisition and processing unit also includes a storage module for data storage and uploading, and an interface for data communication with the management platform.

10. A wire saw cutting device, characterized in that: The device includes a main body and a wire saw cutting monitoring system as described in any one of claims 1 to 9. The main body includes a closed rope with cutting elements along the line, a drive wheel that can drive the rope, a drive motor for driving the drive wheel, a tension wheel for tensioning the rope, a guide wheel for guiding the rope, a feed mechanism for driving the device to feed, and a cooling water mechanism for cooling. The cooling water mechanism includes cooling water pipes and flow control components.

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