Development And Use Of Stone Cutting Saws

In recent years, with the gradual implementation of urban infrastructure construction and western development, the rapid development of expressways across the country, square stone, step stone, roadside stone demand is increasing, greatly promoting the development of stone processing enterprises; At the same time, after China’s accession to the WTO, the export volume of tombstone, square stone and other stones increased gradually, which also led to the rapid development of stone processing enterprises. However, when the traditional large disk stone cutting machine is used to process these blanks, the efficiency is low and the cost is high. The main performance is as follows: more times of up and down blanking, more labor and time consuming to turn over the blanking, higher consumption during operation, and it is not suitable for the condition of fine stone material and small mining of blanking. For this reason, these stone processing plants are in urgent need of equipment that can not only meet the requirements of such stone processing, but also achieve higher production efficiency and lower cost. After a full demonstration, we developed this kind of small bridge diamond disc stone cutting saw, after nearly two years of use, the effect is good, well received by users.

Main USES and characteristics of stone cutting saws

Adopt diamond circular saw blade with a diameter of 1600mm to cut the mined waste materials into gravestone stone, square stone, step stone, kerb stone and other billets; Or the raw materials cut into the board material, can also be used to give the initial cut shape gravestone stone, square stone, step stone and other blank head, edge cutting, etc.

The machine has the following main features:

1, reasonable structure, good stability, large lifting stroke, can achieve secondary cutting, cutting efficiency is high, low cost, cutting surface smooth, good flatness, high rate of finished products, no mechanical breakage and corrosion and pollution.

2, simple operation, high degree of automation, the machine is all used in the electric control cabinet automatic control and semi-automatic control, according to the material of the cut SLATE, can adjust the feeding speed, both safe and can improve the cutting efficiency, electrical parts with interlocking and safety device, so as to ensure the safety and reliability of the equipment work.

3, wide range of application, can process more than 10mm thickness of granite, marble and other plates, tombstone stone, square stone and other stone crafts blank.

Two, the main structure of stone cutting saw

1, columns, skateboarding device: the stone cutting saw column for reinforced concrete columns, column slide guide rail, are installed on board move up and down through screw drive along the guide rail, can travel 1600 mm, can cut a large granite or marble material, a feeding can continuous cutting, greatly saves time, improves the production efficiency, greatly reduces the labor intensity.

2. Beam and internal frame device

The device is composed of a beam and an internal frame, which moves left and right on the beam through the gear transmission, so as to realize the continuous feeding of the cutting process, and the horizontal moving speed of the moving knife can realize the stepless frequency conversion speed regulation, which is applicable to various kinds of stone materials with different hardness.

3. Spindle box device

The device is composed of main box, auxiliary box and flange of cutter disc, which is fixed on the inner frame with bolts. It has compact structure, stable transmission, low noise, high cutting speed and efficiency.

4. Transmission device

This device transmits power through triangle belt and chain. There are five three-phase asynchronous motors in total, which can automatically lift, feed, divide, supply coolant and protect the motor.

5. Workbench device

Adopt rotary trolley device. When the datum of stone is not consistent with the direction of the saw blade, the rotary table can be adjusted to achieve the best cutting position. The trolley has two functions of automatic movement and manual operation.

Installation and commissioning of stone cutting saws

(I) installation of stone cutting saws

1. According to the foundation drawing, professional construction personnel shall operate in strict accordance with the code for construction and acceptance of reinforced concrete projects. The foundation, embedded anchor bolts, size and location of foundation shall meet the requirements of the drawing, and the foundation maintenance period shall not be less than 20 days.

2, foundation maintenance expires after drying, the sawing machine cap on reinforced concrete stand on the top, adjusted the position, and good pressure rail fastening, the two slide guide rail respectively fixed on the column on both sides, with the level of peace feet to adjust the verticality of the slide guide rail with horizontal plane is not more than 0.1 mm, two slide guide rail surface parallelism is not greater than 0.4 mm, and to ensure that the up and down two guide rail center within the same upright surface by the beam frame assembly installed on the slide guide rail, and installed elevator drive screw and wire, commissioning observation condition, and through the strip wire adjustment guide clearance, to ensure steady lifting flexible, No jam and abnormal sound.

3. The horizontal movement of the inner frame on the beam should be flexible without jamming and abnormal sound. The clearance between the inner frame and the beam should be adjusted by the top wire of four tugboats on the inner frame trailer to ensure normal operation.
4. Install the spindle box on the trailer under the inner frame, and adjust the transmission position to ensure the spindle rotates flexibly. Check the verticality between the spindle and the beam with the level meter and the micrometer, and the end face of the flange in the spindle saw blade does not beat more than 0.05mm.
5. The trolley guide rail shall be placed on the flat foundation and fastened with nuts. The two guides shall be equally spaced, parallel to each other and perpendicular to the beam.

6, the installation of the saw blade: first of all, it is necessary to put the blade inner flange fixed on the spindle, and ensure the face runout is greater than 0.05 mm, then the saw blade clamping with flange and bolt on the spindle, and after the great circle outside flange nut and tighten, manually check the circular saw blade face runout, new saw blade is not greater than 0.8 mm, the complex welding blade is not greater than 1.5 mm.

7, the stone saw electrical installation should be undertaken by electrical professionals, must be strictly in accordance with the electrical wiring diagram installation inspection, to ensure that there is no error.

(ii) debugging of saw machine

1, according to the electrical wiring diagram after careful inspection to ensure that there is no power on.

2. Check the fastness of each motor and the tightness of belt and chain by manual turning, and adjust them to the best state.

3, check the operation of the transmission mechanism, to ensure that the operation, mobile flexible, no obvious jam phenomenon, and stable connection.

4. Check the correctness and fastness of each part position.
5. Check the correctness and firmness of each protective (dust proof) device.
6. Check the working condition of each control handle and button, and ensure that they are sensitive and effective.

When all the above inspections are completed, lubricate all the lubricating places and keep the injected oil clean. At this time, part of the test run item by item, namely, test the main drive motor first, check the running condition of the main shaft, and shut down after normal operation; Test the lifting motor, check the lifting and running condition of the beam along the slide guide rail, the machine can be shut down after normal operation; Then test the transversely moving motor to check the transversely moving operation, and the machine can be shut down after normal operation; Then test the motor for auto chip operation. Check the operation and chip condition. The motor can be shut down after normal operation. Finally, the automatic operation was tested to make the saw machine run empty. When all parts of the saw machine were running normally, the load test could be carried out. In the load test, the saw blade was firstly installed, starting from low load, and then gradually increased. In the test process, attention should be paid to check the main motor, transverse motor current changes and other motor load changes, and check the sawing machine parts of the operation and sound, and pay attention to the temperature rise of the bearing is normal.

Four, stone cutting saw running-in and adjustment

After the installation and debugging of the new saw machine is qualified, it can be put into normal operation after proper running-in, which can effectively improve the service life of the stone saw and reduce the applause rate of the stone saw.

In the running-in period, the saw machine should be operated and running-in step by step according to the specified time with different loads, from light to heavy, so as to improve the adaptability of the other parts of the stone cutting saw. Generally speaking, run in no-load for 10-15 hours to observe whether the no-load current of the main engine is normal, and then run in light load for 150-200 hours to observe whether the current of the main engine is normal, and then run in medium load for 150-200 hours to observe the operation of the main engine. Due to the various process factors in the sawing process is more restricted, but also more complex, judging whether the operation is normal, should be stable with each meter indicator, cutting crisp “rustling” sound, the whole machine is running normally, no abnormal sound and jam for the principle.

After the end of the run-in period, a comprehensive inspection and adjustment should be made to the stone cutting saw:

1. Check the lubrication of each lubrication part and add oil again.
2. Release the lubricating oil in the spindle box, worm gear box, reducer and oil tank, and refuel according to regulations (clear the box if necessary, and refuel after cleaning).

3, check the transmission belt, chain tension, and adjust the appropriate.

4, check the sliding parts and lead screw, screw clearance, should not be adjusted.

5. Check the running in of moving parts in each box, especially the bearing clearance, which shall be adjusted if necessary.
6. Check all fasteners and re-tighten them.
7. operation and operating procedures of stone cutting saws
8. Operators should have general knowledge and certain safety knowledge of machinery and electrical appliances, be familiar with equipment performance, and understand the functions of buttons, meters and indicator lights on the control panel.
9. When laying waste materials, sleepers must be placed between the waste materials and the surface of the trolley, and the cushions should be adjusted as required to stabilize the waste materials in the best cutting position (the center of gravity of waste materials should pass through the center of the trolley).
10. In order to ensure the maximum cutting depth, the waste material must be dressed, and the top roughness and levelness of the waste material should be less than 20mm.
11. Adjust the trigger position of left, right, up and down stroke switches correctly. The upper limit switch shall ensure that when the saw blade is in the upper limit, its lowest point is equal to or slightly higher than the highest point of the waste material (no higher than 20mm); The lower stroke switch should ensure that when the saw blade is in the lower limit, it can cut out the required width of the plate. At the same time, it should ensure that the flange clamps the saw blade and the saw blade guard shall not touch the waste materials. The position of the left and right limit switch shall ensure that when the saw blade is in the left and right limit, the center of the spindle will leave the waste material 200mm (cutting depth 20mm), and the left, right, upper and lower limit positions shall not exceed their permitted limit positions.

5, should check before starting the clamping blade flange of whether the fasteners, the stroke switch can self-control, normal availability of cooling fluid rotation with the hand saw blade is flexible, direction of feed obstacles, should pay special attention to the blade can’t contact with waste material, main motor is normal after the operation, to start the feed motor.

6. The thickness of the plate is controlled by the electric control cabinet, and the motor of the trolley is set by the time relay.
7. At the beginning of cutting raw materials, the horizontal moving speed and depth of feeding should not be too large, generally 5-6 mm. After normal cutting, it depends on the hardness of raw materials.

8, the new saw blade cutting waste material should be first, try to cut refractory brick, so that the diamond particles appear, so that the blade blade is sharp. When the saw blade is used for a period of time, if the main motor current is found to be too high, it means that the blade blade is not sharp, then it should be polished with firebrick immediately. Repair grinding method is: the fire brick on the incision, work can repair grinding, but should slow down the speed of the knife to prevent excessive current.

9, during the cutting process, the operator should focus on, pay attention to the instrument instructions and the working condition of the saw machine, pay special attention to the condition of the coolant, found that the current is too large at any time to adjust the feed speed. In case of any abnormal situation, press the emergency stop button immediately.

10. After cutting a piece of SLATE, the saw blade will be automatically lifted and stop automatically when the upper stroke switch is touched. The operator can press the trolley button and the trolley moves to separate the board. After feeding finished, press the automatic button and the equipment will enter the normal state, and so on.
11. After the work, press the total stop button, disconnect the air switch, cut off the power supply and clean up the site.

Six, stone cutting saw maintenance and maintenance

Stone cutting saws in use, there should be strict maintenance and maintenance system.

1. Oil must be filled and changed strictly according to the lubrication requirements.

2, regular inspection of various fasteners are loose phenomenon, should ensure that the fastening.

3. When replacing the diamond saw blade, the end face of the saw blade shall be tested for jumping. The new saw blade shall not exceed 0.8mm, and the re-welding saw blade shall not exceed 1.5mm.

4, check whether the triangle belt is appropriate, whether there is no slip phenomenon, whether the aging. Adjust or replace if necessary.

5. Check whether the centralized lubricating oil road is smooth.

6, often check the control cabinet electrical components, wiring screws are loose phenomenon, whether the action is sensitive.

7. Whether the center of gravity is correct and stable when cutting the blanks, the bottom of the blanks must be left with 10-40mm.
8. Check whether there is any leakage in the spindle box. If it is found, the cause should be found out immediately and measures should be taken to replace the oil.
9. Check whether all electrical appliances are safely grounded.

10, check the movement of the guide strip clearance is appropriate.

Seven, conclusion

This small bridge type golden stone disc stone cutting saw is of high efficiency, low cost, simple operation, high degree of automation and low cost in the processing of tombstone, step stone and square stone, etc., which can realize the secondary cutting, reduce the loading and unloading times and labor intensity, and is a very convenient and practical stone cutting equipment.