How To Ensure Precise Sizing of Flying Shear Blades During The Cutting Process?

Abstract

Flying shear blades play a crucial role in various industries such as steel and paper production. Ensuring precise sizing during the cutting process is essential for product quality and production efficiency. This paper discusses several key aspects to achieve precise sizing of flying shear blades.

1. Introduction

Flying shear blades are used to cut moving materials. Precise sizing is required to meet the specific length requirements of products. Inaccurate sizing can lead to waste of materials, increased production costs, and reduced product quality. Therefore, understanding how to ensure precise sizing is of great significance.

2. Accurate Speed Control

2.1 Synchronous Speed Matching

The speed of the flying shear blades must be precisely synchronized with the speed of the material being cut. Speed sensors are installed on the production line to monitor the material's running speed in real - time. The data is then fed back to the control system of the flying shear. The control system adjusts the rotational speed of the motor driving the blades according to the feedback. This ensures that the horizontal speed of the blades is equal to or slightly greater than the speed of the material, minimizing the relative speed during cutting and thus ensuring accurate sizing.

2.2 Acceleration Control

During the start - up and stop phases of the flying shear, proper acceleration control is necessary. Excessive or insufficient acceleration can cause the blades to reach the cutting position at an incorrect speed, affecting sizing accuracy. By optimizing the parameters of the control system, smooth acceleration and deceleration can be achieved, enabling accurate speed control.

3. Advanced Control Systems

3.1 Automation Control

High - precision programmable logic controllers (PLCs) or digital control systems (DCSs) are used to automate the operation of the flying shear. These systems can calculate the cutting time and position of the flying shear precisely based on the preset sizing length and the material's running speed. They can also adjust the operating parameters of the flying shear in real - time to ensure that each cut meets the sizing requirements.

3.2 Online Monitoring and Feedback

Measurement devices such as laser rangefinders and encoders are used to monitor the running length of the material and the position of the flying shear in real - time. The measured data is fed back to the control system. The control system then makes timely adjustments to the operating parameters of the flying shear and fine - tunes the cutting position to compensate for errors caused by various factors, ensuring sizing accuracy.

4. Precision of Mechanical Structure

4.1 High - Precision Transmission Mechanisms

The transmission system of the flying shear uses precision gears, chains, or synchronous belts. These components are precisely machined and assembled, with minimal transmission errors and clearances. They can accurately transmit the power from the motor to the blades, ensuring that the blades move along the predetermined trajectory and at the correct speed.

4.2 Stable Tool Holder Structure

The tool holder, which is used to install and fix the flying shear blades, is made of high - strength and rigid materials. It is precisely machined and assembled to ensure that the blades are installed in the correct position and orientation. Additionally, reliable positioning and clamping devices are equipped on the tool holder to prevent blade displacement or shaking during cutting, ensuring the accuracy of the cutting position.

5. Blade Design and Maintenance

5.1 Rational Blade Shape and Size

The shape and size of the blades are designed according to the characteristics of the material being cut and the sizing requirements. For thicker materials, larger and stronger blades are used to withstand the high cutting forces without deformation or damage, which could affect sizing accuracy. The blade edge shape is also optimized to ensure clean and accurate cutting, avoiding burrs or tearing that could impact sizing measurement.

5.2 Regular Blade Inspection and Replacement

Flying shear blades wear out during use. Worn blades can affect cutting quality and sizing accuracy. Therefore, regular blade inspections are necessary to measure the degree of wear. When the blades are worn beyond a certain limit, they should be replaced promptly to maintain accurate sizing.

6. Conclusion

Ensuring precise sizing of flying shear blades during the cutting process requires a comprehensive approach that includes accurate speed control, advanced control systems, precision mechanical structures, and proper blade design and maintenance. By addressing these aspects, industries can improve product quality, reduce waste, and enhance production efficiency.