Diamond Saw Blade Performance Testing via Servo Load Control
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Solution Overview
Problem
Conventional methods for testing the cutting performance of diamond saw blades, grinding wheels, and drill bits are inaccurate and non-uniform, leading to inconsistent results due to manual feed methods and rigid constant force testing, which can damage tools or fail to utilize their full potential.
Innovation Solution
A method utilizing an alternating current servo motor and programmable logic controller (PLC) to establish a dynamic closed-loop servo mode for precise control of feed speed and load, ensuring consistent cutting or grinding thrust, and enabling automatic measurement of performance parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual feed method is used for cutting test, then ease of operation is improved, but measurement precision and reliability deteriorate due to instability and operator dependency
Solution Approach 1:
The patent replaces the manual mechanical feed system with an automated servo motor-driven feed system. The servo motor controls the feed rate through electronic signals from the PLC, eliminating manual operation while maintaining ease of use through automated control. This substitution resolves the contradiction by providing both automated precision and operational simplicity.
Solution Approach 2:
The patent implements a closed-loop feedback system where the actual feed rate is continuously monitored and compared with the target feed rate. The PLC adjusts the servo motor output based on feedback signals to maintain consistent feed thrust. This feedback mechanism ensures measurement precision while keeping the system easy to operate through automatic adjustment.
2Reliability
If rigid constant force test method with large hanging weight is used, then reliability is improved by solving randomness, but the tested tool suffers damage due to excessive workload
Solution Approach 1:
The patent transitions from a static rigid constant force system to a dynamic servo-controlled system. The feed rate is dynamically adjusted based on real-time load conditions, allowing the system to maintain reliability through consistent control while adapting to varying material properties and tool conditions to prevent damage from excessive forces.
Solution Approach 2:
The patent changes the control parameter from fixed hanging weight to dynamically adjustable servo motor torque. This allows precise control of the cutting force within an optimal range, ensuring reliable test results while preventing tool damage by avoiding excessive loads that occur with large hanging weights.
3Object-affected harmful factors
If rigid constant force test method with small hanging weight is used, then tool damage is avoided, but the potential of the tested tool is not released resulting in non-objective test results
Solution Approach 1:
The servo-controlled system dynamically adjusts the feed rate to optimize the cutting process. This allows the system to apply sufficient force to release the full potential of the tested tool while maintaining control to prevent damage, achieving both objectives simultaneously through adaptive real-time adjustment.
4Measurement precision
If automatic servo control system is implemented, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The PLC-based control system serves multiple functions: it controls the servo motor, monitors test parameters, processes data, and generates results. This multi-functionality consolidates what would otherwise require multiple separate devices into a single integrated system, reducing overall complexity while maintaining high measurement precision.
Data Source
AI summary
A method for testing cutting performance of a diamond saw blade, relating to a technical field of diamond tool test, is provided, which solves problems of inaccuracy and non-uniformity existing in conventional methods for testing cutting performance of a diamond tool. The method includes steps of: (1) obtaining a set load parameter value, particularly including steps of: controlling a feed amount of the diamond saw blade; finding out a load value K corresponding to a maximum feed amount of the diamond saw blade on a cutting object; and setting M=0.70K-0.85K, wherein M is the set load parameter value; and (2) during cutting, controlling a cutting load value of the diamond saw blade to be 0.90M-1.1M through a servo system. Therefore, uniform three cutting elements of machine and tool, object, and feed thrust are realized, and the performance of the diamond tool is automatically and accurately measured.