WO2007021193A1 - A wire tension system for a diamond wire saw - Google Patents
A wire tension system for a diamond wire saw Download PDFInfo
- Publication number
- WO2007021193A1 WO2007021193A1 PCT/NO2005/000293 NO2005000293W WO2007021193A1 WO 2007021193 A1 WO2007021193 A1 WO 2007021193A1 NO 2005000293 W NO2005000293 W NO 2005000293W WO 2007021193 A1 WO2007021193 A1 WO 2007021193A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wire
- extension
- diamond
- feeding
- cylinder
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/10—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with provision for measuring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
- B23D57/003—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts
- B23D57/0069—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts of devices for tensioning saw wires
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/08—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with saw-blades of endless cutter-type, e.g. chain saws, i.e. saw chains, strap saws
Definitions
- the present invention is related to a wire tension system for a diamond wire saw in a diamond wire machine and a method for controlling such a wire tension system, according to the preamble of the claims.
- a diamond wire machine comprises a frame or body in which a diamond wire is tensioned between two or more wheels secured to the frame where at least one of the wheels is a drive wheel.
- Machines having only two wheels usually are used for simple cutting operations sub-sea and within the quarrying industry.
- three or four wheels usually are used of which one or two are drive wheels.
- the wire has to be pre-tensioned. This usually is achieved with one of the wire wheels in a three wheeled machine or two of the wheels in a four wheels machine being driven.
- the force used will typically be from 100 to 600 kg, depending on the length of the wire.
- a diamond wire comprises of a core wire of steel on to which are threaded cylindrical diamond beads with spacers in between.
- the spacers normally are springs enclosed in plastics or rubber.
- Diamond wires are manufactured as open coil or closed-loop.
- One of the problems is connected with joining the wire.
- an open coil wire it usually is used a sleeve of steel or metal which is clamped against the core wire.
- a closed-loop wire the ends of the wire are weaved together in the production.
- the wire is exposed for huge mechanical loads during operation.
- matters which decide the lifespan of a wire are the number of wire wheels and the diameter of the same, the pre-tension of the wire around the wire wheels, the feeding force used during cutting and which material is to be cut.
- the most common problem with the wires is telescoping. This occurs when the core wire is stretched too much, i.e. plastic deformation occurs in the metal during operation, or the weaving in a closed-loop wire is slipping.
- the core wire therefore will be too long in relation to the number of diamond beads and the spacers and the beads will slip to and fro on the wire during cutting. A result of this is also that the beads are displaced on the wire and cutting is discontinued.
- fractures in the joint also is common. A good control of the wire during operation is the best way to handle these problems.
- a wire extension i.e. a gradually extension of the core wire during a period of time, critical for the lifespan of the wire.
- One of the reasons for this extension of the wire is the pre-tension of the wire. This ensures that the wire is cutting straight with as little wire lag as possible in the cutting object. This pre-tension contributes largely to the wire extension in addition to the mechanical load the wire is exposed from the wire wheels and the cutting object.
- the wire extension according to the present invention provides a solution for tensioning the wire without the disadvantageous mentioned above.
- the system used is defined with the features stated in the patent claims.
- FIG. 1 discloses in figure 1 and overall view of a diamond wire cutting unit
- figure 2 discloses portion of the unit including the tensioning system
- figure 3 discloses schematically the different parts of the tensioning system according to the present invention
- figure 4 discloses a block diagram of the tensioning process.
- a wire tensioning system has to serve several duties, such as providing the wire with a defined pretension, for example 300 kg, take up wire extension during operation thereby to avoid this extension to end up as unnecessary wire lag, provide a spring function when the wire is exposed to strokes from the cutting object, to maintain the pretension also at different feeding forces, and to stabilize the wire for as large a contact surface as possible in the cutting surface.
- the wire tension system comprises a hydraulic cylinder 1 or an electric actuator, an encoder 2, a weight cell 3, as well as necessary hydraulic and electric hoses and cables. Depending on the parameters used, one or more wire tension systems may be used in connection with the same wire saw.
- the hydraulic cylinder 1 is used to provide pretension of the wire and additionally will act as a spring to absorb strokes in the wire during cutting.
- the cylinder 1 is controlled from a control system such as a PLC or computer.
- the encoder 2 is used to provide an accurate position of the cylinder/actuator which especially is of great importance when several wire tension systems are used simultaneously, and also to measure the extension in the wire during cutting.
- the weight cell 3 is used to monitor the pretension force, the feeding force and as well to register quick changes in the load during operation.
- the weight cell 3 as well is monitored by the central control system.
- the feeding speed will never increase beyond what the wire can cope with.
- the most important is to establish a reference measure when a new wire is installed. This is made by providing a stored pretension value to the tension cylinders, for example 250 kg and thereafter measuring a distance between the wire wheels by means of the encoder 2 and thereafter store this value.
- the measured length of the tension cylinder at the time of the first operation with the new wire is the wire length reference.
- the maximum allowed wire length is the wire length reference plus recommended wire extension in %.
- a reference measure For monitoring the extension during cutting a reference measure must be established after the wire has been fully loaded. This means after the pretension is set, the wire motors have started, the feeding is started and the wire has achieved maximum load in the cut for the first time. In such a situation the length of the tension cylinder is measured at maximum pretension plus maximum feeding force, which will be defined as the wire length reference B. The maximum load wire length then will be the wire length reference B plus recommended wire extension in %.
- Figure 4 discloses a block diagram comprising the control of the wire tension system according to the present invention. Any saw action starts with setting the pretension PT. In case the cylinder extension CE is larger than the maximal wire elongation WEM the wire has to be changed. In case not the sawing action may start by starting the feeding operation. In case the pretension PT and the feeding force FF is smaller than the maximum feeding treshold FTl feeding starts again. In case not the feeding is stopped. In case the cylinder extension CE is not smaller than the cylinder extension treshold CET, the wire is changed. In case the cylinder extension CE is smaller or equeal til the cylinder extension treshold CET the minimum feeding treshold has to be ensured and feeding starts over again.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mining & Mineral Resources (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
- Processing Of Stones Or Stones Resemblance Materials (AREA)
Abstract
Method and system for controlling a wire tension system for a diamond wire saw in a diamond wire machine, comprising monitoring the cylinder extension (CE) as a measure of the wire extension and comparing the wire extension with the maximum allowable wire extension (WEM) before starting feeding, monitoring that the set pretension (PT) in addition to the feeding force (FF) is smaller than a maximum feeding treshold (FTl), and monitoring that the cylinder extension (CE is smaller or equal to a cylinder extension treshold (CET).
Description
A wire tension system for a diamond wire saw
The present invention is related to a wire tension system for a diamond wire saw in a diamond wire machine and a method for controlling such a wire tension system, according to the preamble of the claims.
A diamond wire machine comprises a frame or body in which a diamond wire is tensioned between two or more wheels secured to the frame where at least one of the wheels is a drive wheel. Machines having only two wheels usually are used for simple cutting operations sub-sea and within the quarrying industry. For larger or more accurate cutting operations three or four wheels usually are used of which one or two are drive wheels.
To control the wire during cutting the wire has to be pre-tensioned. This usually is achieved with one of the wire wheels in a three wheeled machine or two of the wheels in a four wheels machine being driven. The force used will typically be from 100 to 600 kg, depending on the length of the wire.
Cutting with diamond wires has some limitations connected with to the method as such and especially connected with the diamond wire. A diamond wire comprises of a core wire of steel on to which are threaded cylindrical diamond beads with spacers in between. The spacers normally are springs enclosed in plastics or rubber.
Diamond wires are manufactured as open coil or closed-loop. One of the problems is connected with joining the wire. In an open coil wire it usually is used a sleeve of steel or metal which is clamped against the core wire. In a closed-loop wire, the ends of the wire are weaved together in the production.
Both methods will have disadvantageous. An open coil joint establishes a stiff portion on the wire which are disposed for fractures during use. Connectors with joints are also used to avoid this problem. These, however, weakens substantially the wire.
The biggest problem with closed-loop wires is that the joint expands or slips in the joint. This is especially a problem with relatively short wires were the woven portion also is short. This has connection with the spacers which must be compressed to achieve free ends for the weaving and short wires allowed for only short weaving.
The wire is exposed for huge mechanical loads during operation. Among matters which decide the lifespan of a wire, are the number of wire wheels and the diameter of the same, the pre-tension of the wire around the wire wheels, the feeding force used during cutting and which material is to be cut.
The most common problem with the wires is telescoping. This occurs when the core wire is stretched too much, i.e. plastic deformation occurs in the metal during operation, or the weaving in a closed-loop wire is slipping. The core wire therefore will be
too long in relation to the number of diamond beads and the spacers and the beads will slip to and fro on the wire during cutting. A result of this is also that the beads are displaced on the wire and cutting is discontinued. For open coil wires fractures in the joint also is common. A good control of the wire during operation is the best way to handle these problems. Especially is what is defined as a wire extension, i.e. a gradually extension of the core wire during a period of time, critical for the lifespan of the wire. This is a parameter which up till now has been difficult to control and monitor. One of the reasons for this extension of the wire is the pre-tension of the wire. This ensures that the wire is cutting straight with as little wire lag as possible in the cutting object. This pre-tension contributes largely to the wire extension in addition to the mechanical load the wire is exposed from the wire wheels and the cutting object.
Different technical solutions may be utilized to achieve this pre-tension. Most common is to use a hydraulic cylinder or an electric actuator in the case the tension system should have a linear movement, or a hydraulic or electric motor for solutions incorporating particulate arms. Both of these methods are simple and applicable but do not consider it the wire extension and the wire lag.
The wire extension according to the present invention provides a solution for tensioning the wire without the disadvantageous mentioned above. The system used is defined with the features stated in the patent claims.
The drawing is discloses in figure 1 and overall view of a diamond wire cutting unit, figure 2 discloses portion of the unit including the tensioning system, figure 3 discloses schematically the different parts of the tensioning system according to the present invention, and figure 4 discloses a block diagram of the tensioning process. A wire tensioning system has to serve several duties, such as providing the wire with a defined pretension, for example 300 kg, take up wire extension during operation thereby to avoid this extension to end up as unnecessary wire lag, provide a spring function when the wire is exposed to strokes from the cutting object, to maintain the pretension also at different feeding forces, and to stabilize the wire for as large a contact surface as possible in the cutting surface.
The wire tension system according to the present invention comprises a hydraulic cylinder 1 or an electric actuator, an encoder 2, a weight cell 3, as well as necessary hydraulic and electric hoses and cables. Depending on the parameters used, one or more wire tension systems may be used in connection with the same wire saw. The hydraulic cylinder 1 is used to provide pretension of the wire and additionally will act as a spring to absorb strokes in the wire during cutting. The cylinder 1 is controlled from a control system such as a PLC or computer.
The encoder 2 is used to provide an accurate position of the cylinder/actuator which especially is of great importance when several wire tension systems are used
simultaneously, and also to measure the extension in the wire during cutting. The encoder
2 also is controlled by the control system.
The weight cell 3 is used to monitor the pretension force, the feeding force and as well to register quick changes in the load during operation. The weight cell 3 as well is monitored by the central control system.
There are several ways to control the cutting sequences. The most common is stepping based on time and speed, constant feeding speed or monitored feeding with a combination of these. The best method is considered to be a constant feeding force which is continuously monitored. A set value is stored and the system as such tries to stay as close to this value as possible during operation. This maximizes the cutting speed at any time. Another advantage with this method is that the wear of the diamonds are considered.
The feeding speed will never increase beyond what the wire can cope with.
To measure and monitor the wire extension several parameters must be considered. The most important is to establish a reference measure when a new wire is installed. This is made by providing a stored pretension value to the tension cylinders, for example 250 kg and thereafter measuring a distance between the wire wheels by means of the encoder 2 and thereafter store this value.
The measured length of the tension cylinder at the time of the first operation with the new wire is the wire length reference. The maximum allowed wire length is the wire length reference plus recommended wire extension in %.
For monitoring the extension during cutting a reference measure must be established after the wire has been fully loaded. This means after the pretension is set, the wire motors have started, the feeding is started and the wire has achieved maximum load in the cut for the first time. In such a situation the length of the tension cylinder is measured at maximum pretension plus maximum feeding force, which will be defined as the wire length reference B. The maximum load wire length then will be the wire length reference B plus recommended wire extension in %.
Figure 4 discloses a block diagram comprising the control of the wire tension system according to the present invention. Any saw action starts with setting the pretension PT. In case the cylinder extension CE is larger than the maximal wire elongation WEM the wire has to be changed. In case not the sawing action may start by starting the feeding operation. In case the pretension PT and the feeding force FF is smaller than the maximum feeding treshold FTl feeding starts again. In case not the feeding is stopped. In case the cylinder extension CE is not smaller than the cylinder extension treshold CET, the wire is changed. In case the cylinder extension CE is smaller or equeal til the cylinder extension treshold CET the minimum feeding treshold has to be ensured and feeding starts over again.
Claims
1. Method for controlling a wire tension system for a diamond wire saw in a diamond wire machine, characterized by monitoring the cylinder extension (CE) as a measure of the wire extension and comparing the wire extension with the maximum allowable wire extension (WEM) before starting feeding, monitoring that the set pretension (PT) in addition to the feeding force (FF) is smaller than a maximum feeding treshold (FTl)5 and monitoring that the cylinder extension (CE is smaller or equal to a cylinder extension treshold (CET).
2. Wire tension system for a diamond wire saw in a diamond wire machine, characterized in that a weight cell (3) and a hydraulic cylinder (1) are providing pretension between two consecutive wire wheels (4) of the wire machine, and that an encoder (2) is adapted to provide position signals to a computer for control of the wire tension system, which system also is receiving weight cell signals from the weight cell (3).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/NO2005/000293 WO2007021193A1 (en) | 2005-08-17 | 2005-08-17 | A wire tension system for a diamond wire saw |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/NO2005/000293 WO2007021193A1 (en) | 2005-08-17 | 2005-08-17 | A wire tension system for a diamond wire saw |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2007021193A1 true WO2007021193A1 (en) | 2007-02-22 |
Family
ID=37757794
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/NO2005/000293 WO2007021193A1 (en) | 2005-08-17 | 2005-08-17 | A wire tension system for a diamond wire saw |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2007021193A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ITLU20090011A1 (en) * | 2009-10-28 | 2011-04-29 | Giorgio Dinelli | DEVICE FOR THE CONTROL OF THE DIAMOND WIRE TENSION AND FOR THE CONTROL OF ITS DEFORMATE TO BE USED IN DIAMOND WIRE MACHINES FOR CUTTING STONE MATERIALS |
| CN102114672A (en) * | 2010-11-25 | 2011-07-06 | 新余市银龙机电科技有限公司 | Cone split-type wire winding wheel |
| WO2015198281A1 (en) * | 2014-06-27 | 2015-12-30 | Luca Toncelli | Wire shaping machine for cutting blocks of natural stone material |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2584337A1 (en) * | 1985-07-02 | 1987-01-09 | Ravet Fernand | Tensioning device for machine tool with diamond-impregnated cable |
| FR2633539A1 (en) * | 1988-07-04 | 1990-01-05 | Stricot Francois | Tension generator |
| US5472262A (en) * | 1993-04-28 | 1995-12-05 | Buyens; Marc O. R. G. | Double slot wire sawing apparatus and method |
| JP3105431B2 (en) * | 1995-10-02 | 2000-10-30 | トーヨーエイテック株式会社 | Wire tension control device for wire saw |
| EP1110652A1 (en) * | 1998-08-20 | 2001-06-27 | Super Silicon Crystal Research Institute Corp. | A wire sawing machine with saw wire tension control |
| US20030034022A1 (en) * | 2001-08-14 | 2003-02-20 | Wacker Siltronic Gesellschaft Fur Halbleitermaterialien Ag | Method for separating slices from a hard brittle workpiece, and wire saw for carrying out the method |
-
2005
- 2005-08-17 WO PCT/NO2005/000293 patent/WO2007021193A1/en active Application Filing
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2584337A1 (en) * | 1985-07-02 | 1987-01-09 | Ravet Fernand | Tensioning device for machine tool with diamond-impregnated cable |
| FR2633539A1 (en) * | 1988-07-04 | 1990-01-05 | Stricot Francois | Tension generator |
| US5472262A (en) * | 1993-04-28 | 1995-12-05 | Buyens; Marc O. R. G. | Double slot wire sawing apparatus and method |
| JP3105431B2 (en) * | 1995-10-02 | 2000-10-30 | トーヨーエイテック株式会社 | Wire tension control device for wire saw |
| EP1110652A1 (en) * | 1998-08-20 | 2001-06-27 | Super Silicon Crystal Research Institute Corp. | A wire sawing machine with saw wire tension control |
| US20030034022A1 (en) * | 2001-08-14 | 2003-02-20 | Wacker Siltronic Gesellschaft Fur Halbleitermaterialien Ag | Method for separating slices from a hard brittle workpiece, and wire saw for carrying out the method |
Non-Patent Citations (1)
| Title |
|---|
| DATABASE WPI Week 200057, Derwent World Patents Index; Class P61, AN 1997-267096, XP003008971 * |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ITLU20090011A1 (en) * | 2009-10-28 | 2011-04-29 | Giorgio Dinelli | DEVICE FOR THE CONTROL OF THE DIAMOND WIRE TENSION AND FOR THE CONTROL OF ITS DEFORMATE TO BE USED IN DIAMOND WIRE MACHINES FOR CUTTING STONE MATERIALS |
| CN102114672A (en) * | 2010-11-25 | 2011-07-06 | 新余市银龙机电科技有限公司 | Cone split-type wire winding wheel |
| CN102114672B (en) * | 2010-11-25 | 2014-06-04 | 新余市银龙机电科技有限公司 | Cone split-type wire winding wheel |
| WO2015198281A1 (en) * | 2014-06-27 | 2015-12-30 | Luca Toncelli | Wire shaping machine for cutting blocks of natural stone material |
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