Grinding Wheel Cutting Apparatus for Master Alloy Rod Weight Control
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Solution Overview
Problem
Conventional cutting methods for master alloy rods result in weight errors due to variations in outer diameter, leading to waste and insufficient shrinkage compensation, and involve heavy labor, high pollution, and low automation.
Innovation Solution
A grinding wheel cutting apparatus that uses a laser distance sensor to measure the outer diameter of the rod workpiece, determines the cut-off segment length based on material density and required weight, and performs precise, circular cutting to ensure accurate weight control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed-length cutting is used for master alloy rods, then cutting speed is improved, but weight precision deteriorates due to outer diameter variations
Solution Approach 1:
The patent changes the cutting parameter from fixed length to variable length based on real-time outer diameter measurements. The cutting length is dynamically adjusted according to the measured outer diameter to ensure constant weight, resolving the contradiction between cutting speed and weight precision.
Solution Approach 2:
The patent implements a feedback control system where outer diameter measurements are continuously taken, and the cutting length is adjusted based on this feedback. This closed-loop control ensures that weight precision is maintained while preserving cutting efficiency.
2Device complexity
If conventional cutting methods are used, then device complexity is reduced, but labor intensity and pollution increase
Solution Approach 1:
The patent replaces manual mechanical cutting operations with an automated system that integrates laser measurement and controlled grinding wheel cutting. This substitution reduces labor intensity and improves safety while managing the increased device complexity through integrated automation.
Solution Approach 2:
The system performs self-measurement and self-adjustment of cutting parameters, reducing the need for manual intervention and operation complexity while maintaining simplicity in the overall process flow.
3Productivity
If grinding wheel passes through shrinkage cavity, then cutting is completed, but contamination occurs affecting quality
Solution Approach 1:
The patent performs preliminary measurement of the outer diameter before cutting, allowing the cutting depth to be pre-calculated to stop before reaching the shrinkage cavity. This preliminary action prevents contamination while ensuring complete cutting separation.
Solution Approach 2:
The system takes preliminary measures to prevent the harmful effect of contamination by calculating and controlling the cutting depth to avoid the shrinkage cavity entirely, thus preventing the harmful action before it can occur.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus achieves precise weight control of cut segments, reduces labor intensity, improves safety, and enhances automation, minimizing contamination and waste in the cutting process.
Implementation Method 1
a first laser distance sensor, communicatively coupled to a master controller, is configured to obtain an outer diameter of a rod workpiece
Implementation Method 2
grinding wheel cutting apparatus... performs precise, circular cutting
Data Source
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AI summary
The present invention provides a grinding wheel cutting apparatus comprising a first laser distance sensor (101), a master controller and a grinding wheel. The first laser distance sensor (101) is communicatively coupled to the master controller. The laser distance sensor (101) is configured to obtain an outer diameter of a rod workpiece. The master controller is configured to determine a segment length of a segment to be cut from the rod workpiece based on the outer diameter, a material density of the rod workpiece and a preset segment weight. The master controller is configured to perform a control to circularly cut the rod workpiece with the grinding wheel according to the segment length. The present invention further relates to a cutting method using the grinding wheel cutting apparatus. In the present invention, the cutting and blanking are controlled by the cutting apparatus in a quantitative manner, and the weight of each rod workpiece segment cut off from the rod workpiece is precisely controlled, therefore the weight deviation of the rod workpiece segments can be suppressed, utilization efficiency of the master alloy can be improved, and the requirements on the pressing/breaking equipment can be reduced.