Robot-Arm Wire Saw Cutting With Wire Deflection Feedback
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Solution Overview
Problem
Conventional wire saw devices face challenges in handling large workpieces with curved surfaces, stability in holding workpieces of varying sizes and weights, efficient waste management, and maintaining processing accuracy due to wire deflection, especially when dealing with materials like honeycomb core members that are air-permeable and require precise fixation.
Innovation Solution
A wire saw device equipped with a multi-axis controllable robot arm, air jetting and suction nozzles for waste removal, and a load cell for precise deflection control, allowing for flexible cutting modes and improved mobility, along with suction-based fixation methods for air-permeable workpieces to ensure stable processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional wire saw device with uniaxial processing feed is used, then the device structure is simple, but it cannot flexibly cope with various kinds of workpieces or various processing modes such as curved surface shape
Solution Approach 1:
The patent applies dynamics by replacing the fixed uniaxial processing feed mechanism with a multi-axis controllable robot arm that can dynamically adjust its movement in multiple directions. The robot arm includes multiple joints that enable complex motion trajectories, allowing the wire saw to adapt to various workpiece shapes and processing modes while maintaining a relatively simple overall device structure.
2Object-affected harmful factors
If cooling water is used to cool the cutting portion and wash off cutting waste, then the cutting portion is cooled and waste is removed, but the surrounding equipment is contaminated by cooling water
Solution Approach 1:
The patent replaces the hydraulic cooling water system with a pneumatic system using compressed air. Air blowing nozzles are positioned to blow air onto the cutting portion for cooling and air suction nozzles are positioned to suction cutting waste. This pneumatic approach achieves the same cooling and waste removal functions without the contamination issues associated with liquid cooling water.
3Manufacturing precision
If the wire deflection is not controlled during cutting, then the device operation is simple, but the wire will be disconnected and processing accuracy is reduced
Solution Approach 1:
The patent implements feedback control for wire deflection by positioning a load cell near the dancer roller to detect load changes caused by wire deflection. The control device receives this feedback signal and automatically adjusts the wire feeding amount or winding amount on the reel to maintain proper wire tension and minimize deflection, thereby ensuring processing accuracy without requiring complex mechanical deflection control mechanisms.
4Stability of the object's composition
If a honeycomb core member is held for processing, then the workpiece is secured, but the workpiece cannot be held stably because it is air-permeable
Solution Approach 1:
The patent uses pneumatic suction to hold the air-permeable honeycomb core member. Suction holes are provided in the holding table, and when vacuum is applied, air is suctioned through the honeycomb structure, creating sufficient holding force to secure the workpiece stably during processing. This approach adapts the holding method to work with air-permeable materials effectively.
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 enables efficient cutting of various workpiece shapes and sizes with reduced wire deflection, effective waste management without cooling liquids, and improved processing accuracy, while allowing for easy attachment and detachment of workpieces, thus enhancing operational efficiency and reducing costs.
Implementation Method 1
a dancer roller that applies a predetermined tension to the traveling wire is provided. This device is a wire saw device that includes a load cell that detects a load applied to the dancer roller
Implementation Method 2
a wire saw device equipped with a multi-axis controllable robot arm, air jetting and suction nozzles for waste removal
Implementation Method 3
air jetting and suction nozzles for waste removal, and a load cell for precise deflection control
Implementation Method 4
a wire saw unit connected to the robot arm... configured to cut the workpiece by causing the wire of the wire saw unit to travel and pressing the wire in the cutting processing region against the workpiece while moving the robot arm
Data Source
AI summary
In order to respond flexibly to various processing modes, such as forming curved surface shapes, when cutting a workpiece using a wire saw, this wire saw device (1) is provided with: a single robot arm (2) that is capable of moving freely by means of multi-axis control; a wire saw unit (3) that is detachably connected to the robot arm (2) via a tool changer (7); a wire (8) that spans a plurality of pulleys supported within the wire saw unit (3); and a workpiece cutting zone (20) that is established between the pulleys. The workpiece is cut to a prescribed shape by moving the robot arm (2) in a preset direction while running the wire (8) of the wire saw unit (3) and pressing the wire (8) against the supported workpiece.