Steel roller outer surface sheath cutting system and method

Abstract

The invention relates to a cutting system and method used in aluminum casting lines that enables the removal of the workpiece (17), which consists of a steel roller core with cooling water channels and a cast shell layer with high residual stress mounted on it by heat bonding, by cutting without damaging the steel core. The system includes a locking mechanism (4) that locks the workpiece (17) to the cutting axis, a cutting head unit (5) carrying the cutting motor (6) and cutting disc (7), an X-axis linear feed mechanism (8) that makes this unit rotate left and right, a Y-axis plunge mechanism (9) that performs the stepped plunge movement, a distance sensor (10) that measures the cutting depth instantly, a pressure and escape cylinder (11) with an adjustable pressure throttling valve (12) in the pressure line and a quick relief valve (13) in the escape line, a current measurement module (14) that continuously monitors the current drawn by the cutting motor (6), an operator panel (16) and a control unit (15).The control unit (15) stops the dive in case of a current surge and rescans the same cutting coordinate, and in case of a sudden drop in current, it opens the quick relief valve (13) and pulls the cutter head unit (5) upwards and prevents contact with the steel core with the data from the distance sensor (10).

Description

1 TARIFF Steel roller outer surface sheath cutting system and method Technical Area 5 The invention describes a steel structure used in aluminum casting lines that incorporates water channels. outer surface casings mounted onto the rollers (cores) using a heat transfer method (shell); reaching the end of its service life or existing microcracks progressing and allowing water to seep in. In cases where early dismantling is required due to the risk of leakage, the steel in the internal structure 10 Numerically controlled automatic system that allows for safe removal without damaging the core. It relates to the cutting system and method. State of the Art Current industrial applications use hand tools such as cast shells and spiral grinders. They are cut by operators using entirely manual methods, and They are being dismantled. These traditional practices bring with them fundamental technical problems. These are: - High Occupational Safety Risk and Life-Threatening Hazard: Shells are mounted on the rollers at 20°C. Because it is passed through by heating, very high levels of residue are left in the material after cooling. Stress (thermal stress) builds up. During manual cutting, this stress suddenly increases. its emptying causes the shell to suddenly break during cutting and explode due to the shrapnel effect. This causes the workpiece to break into pieces. The operator's workpiece during cutting... Being right next to it creates a life-threatening risk and danger of injury. 25 - Risk of Damaging the Complex Core (Main Part): Contains water channels. Casting rollers, which contain these components, are expensive to manufacture and are highly sensitive. Since manual cutting relies entirely on the operator's hand dexterity, the cutting stone... Passing the shell and coming into contact with the core caused permanent damage to the roller and rendered it scrap. This can lead to separation. 30 The application with registration number US4091698A was revealed as a result of technical investigations. In summary; "Automatically adjusts the feed rate to maintain a constant chip removal rate." It is a rotary cutting blade control system that changes the cutting blade. It detects the current in a driving electric motor and keeps the motor current constant. It automatically adjusts the speed of progress. The system's current is determined by the operator. 2 Whenever it deviates from a reference value, the blade is moved in or out. It adjusts a pneumatic valve in the pneumatic system that operates the blade support. Control The system also detects when the load on the blade drops below a predetermined level, and Therefore, it contains a circuit that detects when the blade has completed the cutting process, The circuit automatically instructs the pneumatic system to return the blade to its starting position. It gives commands. An additional control circuit works in conjunction with the no-load detection circuit. This saves time and effort when performing numerous cutting operations. To ensure this, the blade is automatically stopped in a position close to the workpiece. It generates commands accordingly. This circuit determines the position of the blade at the beginning of a cutting operation. It works by establishing a reference level that shows...". 10 As can be seen, the invention relates to a rotary cutting blade control system, and in addition to this... a structure that can provide a solution to the disadvantages mentioned above It does not mention it. In conclusion, due to the negative aspects described above and the current solutions, the subject matter... Due to its shortcomings, it has become necessary to make improvements in the relevant technical field. Purpose of the Invention The invention represents a new breakthrough in this field, unlike the structures used in existing technology. The aim is to create a structure with different technical specifications that bring these elements together. The primary purpose of the invention is to create a system used in aluminum casting lines that incorporates water channels. The outer surface is mounted onto steel rollers containing 25 using a heat-sealing method. the shells reaching the end of their service life or existing microcracks progressing and allowing water to enter When it needs to be disassembled because it leads to leakage, the core steel in the internal structure is damaged. a numerically controlled automatic system that allows for safe cutting and removal without requiring any intervention The goal is to establish the cutting system and method. One purpose of the invention is to improve completely manual cutting performed with hand tools such as spiral grinders. By replacing traditional cutting methods with an autonomous cutting cycle, the operator can immediately cut the workpiece. eliminates the life-threatening risk and danger of injury that comes from being near it. to remove. 35 3 Another purpose of the invention is to cool the shell structure, which is heated during assembly. the high level of residual stress (thermal stress) that accumulates afterwards suddenly during cutting to protect against the explosion and shrapnel damage that occurs when the discharge takes place, the cutting operation to be carried out from an area completely isolated from the danger zone to provide. 5 Another purpose of the invention is the protective safety fence and chassis structure with a safety lock on the cell door. This helps to dampen the shell fragments that are ejected during the explosion and prevent them from entering the cell. preventing its exit; preventing physical access to the risky area during the operation, and If the door is open, the system's operation is stopped software-wise. 10 to provide. Another objective of the invention is to completely eliminate the safety fence of the operator control panel (SCADA). by being positioned on a kiosk outside, the input of part diameter / thickness, speed adjustment and process monitoring operations can be carried out from outside the risk area and the human element is at risk 15 The goal is to ensure 100% removal from the area. Another objective of the invention is to reduce the current drawn by the cutting motor to a current that provides an output of 4-20 mA. By continuously monitoring with a measuring module (ammeter), the shell's sudden movement during cutting can be detected. If it cracks or breaks, the mechanical load on the cutting stone is eliminated. 20 By instantly detecting the sudden drop in current, the explosion event can be diagnosed. to provide. Another objective of the invention is to ensure that, when an explosion is detected, there are no interruption elements in the escape path. The quick-release valve channel, which does not contain a cutting head, allows the cutting head to be pulled upwards in milliseconds, 25 by stopping the engine and putting the system into safe standby mode The goal is to prevent hardware damage. Another purpose of the invention is to make the cutting disc work in a hard material region or with high strength. If the motor draws high current due to the encounter, the Y-axis dips 30. suspending the progress until the cutting head's current returns to normal limit values. It should rescan the same X-line and autonomously resume diving from where it left off when the current is balanced. The purpose is to prevent excessive stress on the steel core by ensuring its continuity. Another objective of the invention is to instantly determine the cutting depth via a laser / distance sensor. measured and transmitted to the PLC control unit, and the maximum shell entered via SCADA. 4 By defining the thickness data as a boundary coordinate, the system can determine the coordinate of this boundary. preventing it from going beyond and making contact with the core inside, both through software and hardware. The aim is to ensure that the production of water-channeled castings, which are high-cost and delicate components, is carried out. This eliminates the risk of the rollers being permanently damaged and becoming scrap. is being removed. 5 Another aim of the invention is to determine whether the compressive force applied by the cutting disc to the shell surface... With its adjustable pressure throttling valve, it can be precisely limited to a range of 0.2 - 4.0 bar. Produced via a pneumatic press and escape cylinder, it softens the stone and the material. The goal is to ensure flexible compression. 10 Another objective of the invention is to achieve a screw-driven downward and upward plunge movement of the cutting head. the execution of this diving motion with millimeter precision using jacks and the X-axis Parametrically linked to the number of left-right turns (e.g., two after three turning turns) (by moving down a millimeter) the cutting process is independent of the operator's hand dexterity, 15 The goal is to ensure that it is performed in a repeatable and controlled manner. Another objective of the invention is to position the cutting head preferably five millimeters away from the workpiece surface. The approach should be made by lowering the vehicle at high speed until the critical approach distance is reduced to millimeter precision. The first contact must be securely established by passing through the area quickly (5 mm / min). 20 Another objective of the invention is to keep the heavy workpiece, the rollers, in a safe area outside the cell. loading onto a transport trolley with a crane, smoothly moving along linear rails. conveying into the cutting chamber and position sensors during the operation 25 Thus, it dampens vibrations and prevents part slippage under high mechanical forces. To prevent. Another objective of the invention is a modular axis architecture and recipe-based software infrastructure. Thanks to this, it is possible to cut rolls of different diameters, lengths and weights coming from different casting lines. can be used as a common station in operations and similar facilities in different locations A universal "Roller Revision Cell" that can be directly integrated into dismantling lines. to present. To fulfill the purposes described above, the invention is used in aluminum casting lines. 35 used, steel roller core / guard containing cooling water channels This is a cast iron with high residual stress, assembled using a heat transfer method. The shell layer of a workpiece consisting of a shell / sheath layer is damaged by steel core damage. It is a cutting system that allows for removal by cutting without being given power; its feature is:  Locking mechanism that rigidly locks the workpiece to the cutting axis.  The cutting head unit, which carries the cutting motor and cutting disc components, 5  X- that enables the cutting head unit to make left-right rotations along the roller length. axis linear advancement mechanism,  The cutting head unit performs the downward and upward plunging movement and the plunging action. The Y-axis diving mechanism allows the depth to be kept under control.  Distance sensor that instantly measures and transmits the cutting depth, 10  The cutting disc produces the pressing force on the shell surface at the inlet of the printing line. adjustable pressure throttling valve, with no throttling element in the escape line. Pressure and escape cylinder with quick release valve, which does not contain  Current measurement module that continuously monitors and transmits the current drawn by the cutting motor,  Operator panel where geometric parameters such as shell thickness and roller diameter are entered, 15 cutting limit according to the parameters entered via the operator panel. defining the coordinates; Y-axis dip if the current from the current measurement module increases. The mechanism stops the progress, allowing the current to reach the circuit breaker head unit within the normal limits. Continue linearly along the X-axis using the same cutting coordinate until it reaches the specified values. Re-scanned via the mechanism and dive when the current is balanced. continuing the movement from where it left off, If the current from that current measurement module suddenly drops, it will quickly By opening the relief valve, the cutting head unit is pulled upwards in milliseconds. 25, which stops the engine and puts the system into safe standby mode by monitoring the depth data coming from that distance sensor, the entered shell thickness a cutting mechanism that stops the process when the limit is reached and prevents the steel from coming into contact with the core. control unit It includes. The structural and characteristic features and all the advantages of the invention are given in the figures below. Thanks to the detailed explanation written with references to the figures, it becomes clearer. This will be understood, and therefore the evaluation should also take these figures and detailed explanations into account. It must be done by taking it. 35 Figures that will help understand the invention. 6 Figure 1 shows a general representation of the system that is the subject of the invention. Figure 2 shows a perspective of the locking mechanism used in the system that is the subject of the invention. It is a representation. Figure 3 shows a perspective view of the pressure and escape cylinders used in the system that is the subject of the invention. It is a representation. Figure 4 shows the feed mechanism and cutting head unit used in the system that is the subject of the invention. It is a perspective representation. Figure 5 shows the valves, current measurement module, and control used in the system that is the subject of the invention. This is a perspective view of unit 10. The drawings do not necessarily need to be scaled and are necessary for understanding the invention. Details that are not present may have been overlooked. Furthermore, at least to a large extent... Elements that are identical or at least have substantially identical functions are numbered the same. It is shown. 15 Explanation of Part References 1. Protective safety fence 2. Safety locked cell door 20 3. Roller transport trolley 4. Locking mechanism 5. Cutting head unit 6. Cutting motor 7. Cutting disc 25 8. X-axis linear movement mechanism 9. Y-axis plunging mechanism 10. Distance sensor 11. Printing and escape cylinder 12. Adjustable pressure throttling valve 30 13. Quick relief valve 14. Current measurement module 15. Control Unit 16. Operator panel 17. Workpiece 35 7 Detailed Description of the Invention In this detailed explanation, the preferred configurations of the invention are not merely for better understanding the subject. in order to facilitate understanding and without imposing any limiting effects It is explained. 5 The invention describes a steel structure used in aluminum casting lines that incorporates water channels. outer surface casings mounted onto the rollers (cores) using a heat transfer method (shell); reaching the end of its service life or existing microcracks progressing and allowing water to seep in. In cases where early dismantling is required due to the risk of leakage, the steel in the internal structure 10 Numerically controlled automatic system that allows for safe removal without damaging the core. It relates to the cutting system and method. The elements and functions used in the system and method that are the subject of the invention are as follows: Protective safety fence (1) encloses the machine perimeter in accordance with safety standards, It is a robust fence and chassis structure. It forms the isolated cell architecture of the system and the process. shrapnel is effective when the shell suddenly breaks apart (explodes). by dampening the particles, preventing them from escaping the cell and causing harm to the environment. obstacles. 20 The safety-locked cell door (2) provides access to the cell and is kept closed throughout the operation. It is a safety-locked door. It prevents physical access during the operation, thus posing a risk to the operator. It prevents access to the area; if left open, it software-wise stops the system from working. The roller transport trolley (3) is parked outside the cell and the workpiece (17) crane It is the load-bearing element onto which the load is placed, centered by means of a mechanical locking mechanism operated by the operator. after being opened, to the cutting position inside the cell along the linear line They are transported without jerking; after slaughter, they are moved out of the cell. It allows the roller to be removed with the help of a crane. 30 The locking mechanism (4) is activated by a command given via the operator panel (16). It is a pneumatic mechanism. The roller conveyor (3) and the workpiece (17) on it, Position sensors control the cutting axis, rigidly locking it in place. Cutting It maintains the rigidity of the roller, which is subjected to high mechanical forces during operation, and reduces vibration by 35. 8 It completely prevents damping and part slippage. It deactivates when the cutting is complete. This allows the car to be evacuated. Cutting head unit (5), cutting motor (6) and cutting disc (7) that perform the cutting operation It is the unit that supports axial movements by carrying its components. The x-axis is linear 5 It is brought to the starting reference point by means of the advancement mechanism (8) and the right-left section It performs its rounds; gradually descends via the Y-axis diving mechanism (9). It is submerged. If an explosion is detected, it is launched upwards at the speed of light, and when the cutting is complete, it is then launched back up. It is towed to the upper parking position. The cutting motor (6) produces the torque and high rotational speed required by the cutting disc (7) It is the drive motor that provides the mechanical cutting power. The current it draws is measured by the current measurement module (14) It is constantly monitored by them. The cutting disc (7), preferably 230 mm in diameter, rotates to cut the shell / sheath material 15 by providing linear abrasion, it creates the cutting depth and cutting line. It is a component. X-axis linear feed mechanism (8), with driver-controlled motor equipment, cutting head unit (5) homogeneous and adjustable along the roller length on linear rails 20 It is the mechanism that enables the cutting motor (6) to make right-left turns at high speed. If current is drawn, it performs a second scan of the same section coordinate. The Y-axis plunge mechanism (9) consists of screw jacks, which lower the cutting head unit (5). and performs its upward movement with millimeter precision and controls the diving depth 25 It is the mechanism that keeps the head under the workpiece (17) surface at a distance of 5 mm. It accelerates at high speed until it reaches the critical approach distance, and then reduces the remaining distance at a speed of 5 mm / min; In automatic cycling, the X-axis is parametrically dependent on the number of revolutions (e.g., every three revolutions). It performs a gradual diving motion (2 mm). The distance sensor (10) measures the cutting depth in real-time and sends it to the control unit (15) It is a transmitting laser / distance sensor. It is based on the shell thickness limit entered via the operator panel (16). When reached, it prevents contact with the steel core underneath. The pressure and escape cylinder (11) applies an ideal force of 35 to the shell surface of the cutting disc (7) during cutting. It is a pneumatic cylinder that enables the application of pressure, with the pressure adjustable between 0.2 and 4.0 bar. 9 adjustable pressure throttling valve (12) forming the line, quick pull-up line There is a relief valve (13). In case of emergency explosion, the main unit (5) is thrown upwards. is an agent. The adjustable pressure throttling valve (12) is located at the inlet of the pressure line of the pressure and escape cylinder (11). It is a shut-off valve. It even limits the pressure of the incoming air to between 0.2 and 4.0 bar. It allows the disc (7) to press softly and flexibly on the material. The quick release valve (13) is located in the escape line of the pressure and escape cylinder (11) and has no line It is a valve that does not contain a throttling element. In emergency situations, it instantly releases air pressure, reaching 10 It pulls the cutting head unit (5) upwards in milliseconds. The current measurement module (14) is connected to the line of the cutting motor (6) and the current drawn is 4-20 mA. It is an ammeter that continuously monitors the signal. A sudden drop in amperage can cause the shell to explode or... It was diagnosed that the cutting disc (7) was broken and the material resistance could not be cut due to high amperage. 15 and transmits it to the control unit (15). The control unit (15) processes all sensor data, current signals and safety interlocks. It is the PLC unit that distributes autonomous commands to motor drivers and pneumatic valves. Operator According to the geometric parameters entered via panel (16), the cutting boundary coordinates are 20 The definitions monitor the depth data from the distance sensor (10); in case of high current suspends the submersible and opens the quick relief valve (13) in case of a sudden drop in current to ensure the system is safe. It puts it into standby mode. The operator panel (16) is mounted on a kiosk completely outside the protective safety fence (1) 25 It is a positioned SCADA interface. The operator can see the roller diameter and from outside the hazardous area. It allows input of geometric parameters such as shell thickness, speed adjustment, locking and parking. It allows him to issue commands and monitor the process remotely. The workpiece (17) is fitted with a steel roller core with cooling water channels inside and 30 cast shell layer with high residual stress, assembled by heat transfer method It is the main production component. It is fed into the system to be cut and removed from its outer shell. The autonomous and safety-oriented operating principle of the system described in the invention allows for a single operation without mutual verification. Sequential control loops and dynamic feedback architecture that do not allow for the next stage 35 This is achieved with a system that provides a protective layer resistant to possible part ejection. It has an isolated cell architecture surrounded by a safety fence (1) and chassis structure, and this cell The cell door (2) providing access is kept closed throughout the operation. Security is ensured. The workpiece to be processed (17) is on roller conveyor 5 parked outside the cell. The trolley (3) is loaded onto the crane by means of a crane, centering it. The mechanical locks are engaged by the operator. Opened roller conveyor (3), cutting inside the cell along the linear line It is sent to its location. With the command given via the operator panel (16) located outside the cell. The locking mechanism (4) is activated and the roller carriage (3) and the workpiece on it are engaged. (17) It is rigidly locked to the cutting axis. 10 During the pre-cutting preparation phase, the operator manually measures the shell thickness and the roller. By entering the diameter geometric parameters into the system via the operator panel (16), the control unit (15) defines the cutting boundary coordinates. With the initiation of the cycle, the cutting head Unit (5) moves along linear rails via X-axis linear movement mechanism (8) 15 It is brought to the starting reference point. Simultaneously, the cutting motor (6) is driven. The cutting disc (7) is started to rotate. The cutting head unit (5), Y-axis plunge mechanism (9) is lowered at high speed until a distance of 5 mm remains from the workpiece (17) surface; The remaining 5 mm critical approach distance is controlled by the operator at a millimeter-safe speed (5 The cutting disc (7) makes its first contact with the work surface by passing through (mm / min) and automatic cutting 20 It is started. Cutting head unit (5) in automatic cutting cycle, X-axis linear feed mechanism (8) It performs the linear cutting route by making right-left turns at the speed determined by the drive. Cutting The mechanical pressure force required for the cutting disc (7) to penetrate the material during the process is 25 The pressure of the air coming into this cylinder is produced by the escape cylinder (11) and the pressure of the air coming into this cylinder, The pressure is precisely controlled between 0.2 - 4.0 bar with the adjustable pressure throttling valve (12). As the cutting head unit (5) completes its left-right rotations, the Y-axis plunging mechanism (9) lowers the head. gradually and parametrically dependent on the number of X-axis rotations (e.g., every three It plunges downwards (2 mm per turn). The cutting depth is continuously measured by the distance sensor (10) at 30 measured and monitored by the control unit (15) until the final limit value entered from the beginning. When this is reached, the control unit (15) stops the cutting process and the steel core contact is definitely reached. It is blocked. During cutting, the cutting disc (7) must be in a hard material area or with high strength 35 When it encounters a strain, the cutting motor (6) starts to draw more current from the mains. 11 The current measurement module (14) connected to the motor line measures this current rise instantaneously with a 4-20 mA signal. It transmits to the control unit (15). The system avoids overloading the steel core by using the Y-axis. The immersion mechanism (9) stops its advancement. The cutting head unit (5) stops the current within the normal limit. until the values ​​fall to the same section via the X-axis linear advancement mechanism (8) It cleans the material by scanning the coordinate once more; when the current is balanced, it dives downwards 5 It continues autonomously from where it left off. The high-stress shell layer on the workpiece (17) suddenly breaks during cutting or If it bursts, the mechanical load on the cutting disc (7) disappears within milliseconds and the cutting The current of the motor (6) drops suddenly. The current measurement module (14) detects this sudden drop and controls 10 It transmits to the control unit (15). The control unit (15) is located on the printing and escape cylinder (11) and By opening the quick relief valve (13) which contains no throttling elements in the line, the cutting head It launches the unit (5) upwards at the speed of light, stops the motor and puts the system into safe standby mode. Shell fragments ejected during the explosion are protected by the safety fence (1). It is extinguished, preventing it from escaping the cell. 15 When the cutting process is successfully completed along the defined shell thickness, the operator panel will display the message. With the command given via (16), the cutting head unit (5) is pulled to the upper parking position. Locking The mechanism (4) is deactivated and the roller conveyor (3) moves out of the cell. It is inspected. When the car reaches the safe zone, 20... (The sentence is incomplete and unclear in the original Turkish) The roller is removed from the vehicle with the help of a crane, ensuring the operation cycle is completed safely. It is completed. The machine described in this invention is designed for the periodic operation of continuously running rollers in aluminum casting plants. A fully enclosed and self-contained 25 at the heart of maintenance, repair and overhaul lines. It functions as a "Roller Revision Cell". The system features a modular axis architecture and Thanks to its recipe-based software infrastructure, it can process different diameters, lengths, and sizes from all casting lines. It can be used as a common station in the cutting operations of cores of varying weight; also It can also be directly integrated into similar dismantling lines in different locations. The steps involved in the process of implementing the system described in the invention are listed below:  The locking mechanism (4) is activated by the command given via the operator panel (16). by means of the roller carriage (3) and the workpiece (17) on it to the cutting axis. rigid locking, 12  Geometric parameters of shell thickness and roller diameter on the operator panel (16) By entering the system via, the cutting boundary coordinates are entered on the control unit (15). definition,  cutting head unit (5), via X-axis linear feed mechanism (8) Bringing the device to the starting reference point on linear rails and simultaneously 5 by driving the cutting motor (6) to rotate the cutting disc (7) start,  The cutting head unit (5), through the Y-axis plunge mechanism (9) the workpiece (17) lowered at high speed until it is a certain distance from the surface,  by passing the remaining critical approach distance at a lower speed, the cutting disc (7) 10 making initial contact with the part surface and starting the automatic cutting process,  The cutting head unit (5) is driven by the X-axis linear feed mechanism (8). It executes the linear cutting path by making left turns and applying the necessary pressure for the cut. the force is controlled by the adjustable pressure throttling valve (12) and Produced by escape cylinder (11), 15  Y-axis diving mechanism parametrically dependent on the number of left-right turns (9) lowering the cutting head unit (5) gradually,  The cutting depth is continuously measured by means of the distance sensor (10) and the control unit (15) to be supervised by,  The current drawn by the cutting motor (6) is continuously measured by the current measurement module (14) at 20 by monitoring and transmitting to the control unit (15),  the cutting disc (7) encounters a hard material area or high strength If the current increases due to strain, the steel core will be overloaded. Stopping the advance of the Y-axis diving mechanism (9) in order to avoid being loaded,  The cutting head unit (5) continues cutting until the current drops to normal limit values. once again the coordinate of the X-axis linear advancement mechanism (8) by scanning and cleaning the material, and the diving action remains when the current is balanced. Continuing autonomously from the ground,  Cutting due to sudden cracking or bursting of the shell layer during cutting the mechanical load on the disc (7) is eliminated and the current of the cutting motor (6) is 30 If it falls suddenly, this sudden drop is detected by the current measurement module (14) detected and transmitted to the control unit (15),  In case of sudden current drop, the control unit (15), pressure and escape cylinder (11) By opening the quick release valve (13), it pulls the cutter head unit (5) upwards in milliseconds, stopping the cutting motor (6) and putting the system into safe standby mode, 35 13  The distance sensor (10) indicates that the entered final shell thickness has been reached. The cutting process is stopped upon verification and the system's contact with the steel core is confirmed. prevention.

Claims

14 REQUESTS 1. Steel used in aluminum casting lines, containing cooling water channels. roller core / guard and high-performance heat-bonded mounting system mounted on top of it. shell 5 of a workpiece consisting of a cast shell / sheath layer with residual stress (17) a cutting system that allows the layer to be cut and removed without damaging the steel core Its characteristic is;  locking mechanism that rigidly locks the workpiece (17) to the cutting axis. mechanism (4),  Cutting head unit carrying the cutting motor (6) and cutting disc (7) components 10 (5),  X- which enables the cutting head unit (5) to make right-left turns along the roller length. axis linear advancement mechanism (8),  The cutting head unit (5) performs the downward and upward diving movement and diving Y-axis diving mechanism (9), which ensures that the depth is kept under control, 15  Distance sensor (10) that measures and transmits the cutting depth in real time.  The cutting disc (7) produces the pressing force on the shell surface at the printing line inlet adjustable pressure throttling valve (12), but no throttling element in the escape line. Pressure and escape cylinder (11) with quick release valve (13) which does not contain,  Current measurement module (14) which continuously monitors and transmits the current drawn by the cutting motor (6), 20  Operator panel where geometric parameters such as shell thickness and roller diameter are entered. (16), cutting limit according to the parameters entered via the operator panel (16) defining the coordinates; If the current from the current measurement module (14) increases, the Y-axis will be 25 By stopping the progress of the plunge mechanism (9), the current flows to the cutter head unit (5). The same intersection coordinate on the X-axis until it falls within the normal limit values. Re-scanned via linear advancement mechanism (8) and current When balanced, it resumes the diving motion from where it left off. If the current from the current measurement module (14) drops suddenly, the fast 30 by opening the relief valve (13) and pulling the cutting head unit (5) upwards in milliseconds, stopping the cutting motor (6) and putting the system into safe standby mode, by checking the depth data from the distance sensor (10) the entered shell a cutting mechanism that stops when the thickness limit is reached and prevents contact with the steel core. control unit (15) 35 It includes.

2. A cutting system conforming to Claim 1, characterized by its isolation system that encloses the machine perimeter. the cell architecture and the shrapnel effect that is ejected when the shell explodes a durable material that dampens the particles and prevents them from escaping the cell. The structure includes a protective safety fence (1). 5 3. An interrupt system that conforms to claim 1 or 2, and whose characteristic is that it provides access to the cell. prevents physical access during the operation and, if left open, the system It includes a safety-locked cell door (2) that stops its operation software-wise.

4. A cutting system in accordance with Claim 1, the feature of which is that the protective safety fence (1) is completely located on a kiosk outside, with speed control, locking and parking commands. an operator with a SCADA interface that enables the data transfer and remote monitoring of the process It includes panel (16).

5. A cutting system that conforms to Claim 1, and its characteristic is that the workpiece is parked outside the cell. part (17) was centered by means of a crane and loaded onto it and mechanical locks Once opened, it moves smoothly along the linear path to the cutting position inside the cell. It includes a roller transport cart (3) which is shipped.

6. It is a cutting system that complies with Claim 1, and its feature is given via the operator panel (16). Activated by command, the roller carriage (3) and the workpiece (17) on it are positioned. The sensors lock the device onto the cutting axis and deactivate it when the cut is complete. It includes a pneumatic locking mechanism (4) that enables the evacuation of the car (3).

7. A cutting system that conforms to Claim 1, and its feature is that it is connected to the line of the cutting motor (6). and includes a current measurement module (14) that continuously monitors the current drawn with a 4-20 mA signal.

8. A cutting system conforming to Claim 1, with the characteristic of being able to withstand pressures between 0.2 and 4.0 bar. It includes an adjustable pneumatic pressure and escape cylinder (11). 30 9. A cutting system conforming to Claim 1, characterized by its ability to reduce the air pressure entering the printing line. By limiting the cutting disc (7) to between 0.2 - 4.0 bar, the material is made soft and flexible. adjustable pressure throttling valve (12) configured to allow it to press It includes. 35 16 10. A cutting system that conforms to Claim 1, and its feature is the movement of the cutting head unit (5). Y-axis plunging mechanism consisting of screw jacks that operate with millimeter precision. (9) is included.

11. A cutting system conforming to Claim 1, characterized by its automatic cycle with 5 revolutions per X-axis. to perform a step-by-step diving motion while parametrically linked It includes a structured Y-axis diving mechanism (9).

12. A cutting system conforming to claim 1 or 11, characterized by a 2 mm downward movement every three right-left turns. Y-axis diving mechanism structured to carry out the diving motion (9) 10 It includes.

13. A cutting system that conforms to claim 1 or 11, and whose feature is; cutting head unit (5) work until the distance from part (17) to the surface is 5 mm, at high speed, the remaining critical approach The Y-axis plunging system is configured to lower the depth at a speed of 5 mm / min. its mechanism is (9).

14. A cutting system conforming to Claim 1, characterized by a laser that measures the cutting depth in real time. It contains a distance sensor (10) consisting of a sensor.

15. A cutting system conforming to Claim 1, characterized by its linear feed in the X-axis. its mechanism (8), cutting head unit (5) on linear rails homogeneous and Driver-controlled motor equipment that allows it to make left and right turns at an adjustable speed. It includes.

16. A cutting system in accordance with Claim 1, its feature is a cutting disc with a diameter of 230 mm (7) It includes.

17. It is a cutoff system that complies with Claim 1, and its feature is that it receives all sensor data, current signals and By processing safety interlocks, autonomous commands are given to motor drivers and pneumatic valves. 30 It includes a control unit (15) consisting of a PLC unit that distributes.

18. Steel used in aluminum casting lines, containing cooling water channels. roller core / guard and high-performance heat-bonded mounting system mounted on top of it. shell 35 of a workpiece consisting of a cast shell / sheath layer with residual stress (17) 17 a cutting method that allows the layer to be cut and removed without damaging the steel core Its characteristic is;  The locking mechanism (4) is activated by the command given via the operator panel (16). by means of the roller carriage (3) and the workpiece (17) on it to the cutting axis. rigid locking, 5  Geometric parameters of shell thickness and roller diameter on the operator panel (16) By entering the system via, the cutting boundary coordinates are entered on the control unit (15). definition,  cutting head unit (5), via X-axis linear feed mechanism (8) Bringing the device to the starting reference point on linear rails and simultaneously 10 by driving the cutting motor (6) to rotate the cutting disc (7) start,  The cutting head unit (5), through the Y-axis plunge mechanism (9) the workpiece (17) lowered at high speed until it is a certain distance from the surface,  by passing the remaining critical approach distance at a lower speed, the cutting disc (7) 15 making initial contact with the part surface and starting the automatic cutting process,  The cutting head unit (5) is driven by the X-axis linear feed mechanism (8). It executes the linear cutting path by making left turns and applying the necessary pressure for the cut. the force is controlled by the adjustable pressure throttling valve (12) and Produced by escape cylinder (11), 20  Y-axis diving mechanism parametrically dependent on the number of left-right turns (9) lowering the cutting head unit (5) gradually,  The cutting depth is continuously measured by means of the distance sensor (10) and the control unit (15) to be supervised by,  The current drawn by the cutting motor (6) is continuously measured by the current measurement module (14) 25 by monitoring and transmitting to the control unit (15),  the cutting disc (7) encounters a hard material area or high strength If the current increases due to strain, the steel core will be overloaded. Stopping the advance of the Y-axis diving mechanism (9) in order to avoid being loaded,  The cutting head unit (5) will cut the same section until the current drops to normal limit values. once again the coordinate of the X-axis linear advancement mechanism (8) by scanning and cleaning the material, and the diving action remains when the current is balanced. Continuing autonomously from the ground,  Cutting due to sudden cracking or bursting of the shell layer during cutting the mechanical load on the disc (7) is eliminated and the current of the cutting motor (6) is 35 18 If it falls suddenly, this sudden drop is detected by the current measurement module (14) detected and transmitted to the control unit (15),  In case of sudden current drop, the control unit (15), pressure and escape cylinder (11) By opening the quick release valve (13), it pulls the cutter head unit (5) upwards in milliseconds, stopping the cutting motor (6) and putting the system into safe standby mode, 5  The distance sensor (10) indicates that the entered final shell thickness has been reached. The cutting process is stopped upon verification and the system's contact with the steel core is confirmed. preventing, It includes the steps of the process.

19. A cutting method conforming to claim 18, characterized by the fact that the plunging motion occurs in all three right-left directions. The process involves performing the steps gradually, with a 2 mm increment per turn.

20. A cutting method in accordance with claim 18, the characteristic of which is that it comes to the pressure and escape cylinder (11). air pressure can be adjusted to a range of 0.2 - 4.0 bar with the adjustable pressure throttling valve (12). The limitation is that it includes the process step.

21. A cutting method in accordance with claim 18, the feature of which is that the current is measured by the current measurement module (14) The process involves monitoring with a 4-20 mA signal.

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