Ingot Cutting Wire Load Sensing and Tension Control
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Solution Overview
Problem
Ingot cutting apparatuses using wire saws face issues with wire breakage due to uneven cutting states between the new wire side and old wire side, where the longer wire contact leads to diamond grain removal and reduced cutting ability, causing deep grooves on the new wire side and shallow grooves on the old wire side, resulting in wire bending and breakage.
Innovation Solution
The apparatus incorporates load sensors attached to the slicing table to measure loads and bending of the wire on both the new and old wire sides, allowing for the detection of differences in cutting states and tension, enabling control measures to prevent wire breakage by adjusting the cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire is used for a long distance to cut the ingot, then the productivity is improved, but the diamond grains are removed from the wire surface causing cutting ability to decrease
Solution Approach 1:
The wire running direction is dynamically reversed to alternate between forward and backward directions. This allows the wire to be used effectively on both sides of the ingot, extending its usable life and maintaining cutting ability throughout the cutting process
2Duration of action of moving object
If the wire runs in forward and backward directions alternately, then the wire lifespan is extended, but the cutting grooves become uneven causing wire bending and breakage
Solution Approach 1:
Load sensors detect the cutting load differences between the new wire side and old wire side in real-time. This feedback information is used to control the pressing force, ensuring that the ingot is pressed with appropriate force on each side to maintain uniform cutting grooves and prevent wire breakage
Solution Approach 2:
The pressing force parameter is dynamically adjusted based on the wire side being used. The control device modifies the pressing force to compensate for the different cutting states of new and old wire sides, maintaining optimal cutting conditions throughout the wire's lifespan
3Productivity
If the ingot is pressed against the wire on the old wire side with shallow cutting grooves, then the cutting continues, but the wire bends significantly and breaks
Solution Approach 1:
The pressing force is dynamically adjusted based on the wire side being used. When cutting on the old wire side with shallower grooves, the pressing force is reduced to prevent excessive wire bending and breakage, while maintaining sufficient force for continuous cutting
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 solution effectively eliminates the difference in tension between the new and old wire sides, preventing wire breakage by detecting and adjusting for load and bending differences, ensuring consistent cutting performance and extending wire lifespan.
Implementation Method 1
a measuring device that measures loads applied to the ingot or the amount of bending of the wire on a new wire side where new wire is supplied to the ingot and an old wire side where old wire is recovered
Data Source
AI summary
In an ingot cutting apparatus that cuts an ingot using a plurality of stretched wires, load sensors are provided on the new wire side and the old wire side of the ingot, and loads applied to the new wire side and the old wire side of the ingot are measured using the load sensors on the new wire side and the old wire side. When measuring the loads, for example, the center of moment about the X-axis that is the running direction of the wire is calculated. When the deviation from the center of gravity of the ingot is greater than or equal to a reference value, notification for replacement of the wire, control of the conveying speed of the wire, control of the pressing speed of the ingot, and so forth are performed through a control unit.