Modeling and Tension Characteristic Analysis of Low-carbon Sawing System for Large Stone Slabs

doi:10.3969/j.issn.1004-132X.2026.10.005

Abstract

Abstract:

In the multi-wire sawing of large stone slabs， severe wire-net tension fluctuations can cause unstable machining quality and wire breakage， resulting in material waste and extra energy consumption. To address this issue， a coupled dynamic model of the wire-storage chamber and the cutting chamber was established， enabling refined modeling of the tension of an individual cutting wire and the construction of the overall wire-net tension state. The model was verified through MATLAB/Simulink simulations and experiments. The results show that increasing the wire-travel speed and the main-roller radius increases the average tension in the cutting chamber by 10.8% and 9.6%， respectively， under the specified operating conditions， while increasing the main-roller acceleration suppresses the tension peak and reduces the average tension by 5.5%. Radius disturbances of the take-up and pay-off rollers have little influence on the cutting-chamber tension because of the tension-arm buffering mechanism. Optimizing wire-net tension characteristics helps improve cutting stability and quality consistency， reduce wire-breakage and rework risks， increase material yield， and reduce ineffective energy consumption.

Key words: green manufacturing, stone processing, multi-wire sawing, dynamic modeling, dynamic characteristics

摘要：

在石材大板多线切割技术中，线网张力剧烈波动易引发加工质量不稳和断线故障，进而造成材料浪费与附加能耗。针对该问题，建立了包含储线室与切割室的完整耦合动力学模型，实现了对单根切割线张力的精细化建模及线网整体张力状态的构建，并通过 MATLAB/Simulink 仿真与实验进行了验证。研究结果表明：走线速度和主辊半径增大会提高切割室张力水平，在设定工况下二者引起的平均张力增幅分别为10.8%和9.6%；提高主辊加速度可有效抑制张力峰值，并使平均张力下降5.5%；储线室收放线辊半径扰动可被张力臂缓冲环节有效隔离，对切割室张力影响较小。优化线网张力特性有助于提高切割稳定性和质量一致性，降低断线与返工风险，从而提高出材率并降低无效能耗。

关键词: 绿色制造, 石材加工, 多线切割, 动力学建模, 动态特性

CLC Number:

TH113

ZHAN Chenhan, YIN Fangchen, KONG Kai, WU Songyuan. Modeling and Tension Characteristic Analysis of Low-carbon Sawing System for Large Stone Slabs[J]. China Mechanical Engineering, 2026, 37(10): 2428-2437.

詹晨涵, 尹方辰, 孔凯, 吴崧源. 石材大板低碳切割系统建模及张力特性分析[J]. 中国机械工程, 2026, 37(10): 2428-2437.

Figures/Tables 17

Fig.1 Multi-wire sawing equipment structure for stone slabs

Fig.2 Dynamic model of the unwinding module

Fig.3 Dynamic model of the traversing module

Fig.4 Dynamic model of the tension arm module

Fig.5 Dynamic model of the main roller

Fig.6 Wrap angle model

Fig.7 Overall Simulink model of the multi-wire sawing system

Tab.1 Simulation parameters of the main roller module

物理量	数值
主辊电机总转动惯量J₉/（kg·m²）	0.0187
主辊电机转矩常数K_t9/（N·m·A^-1）	0.87
主辊电机反电动势系数K_e9/（V·（rad/s）^-1）	1.146
主辊电机电感L₉/H	0.0074
主辊电机电阻R₉/Ω	2.03
主辊总黏性摩擦因数b₉/（N·s·m^-1）	0.01
罗拉轮绕线半径r₉/m	0.04
切割线的弹性模量E/MPa	100
切割线的横截面积A/m²	0.000 000 16
时间常数C	5.6
切割线直径d/m	0.000 45

Fig.8 Simulated wire tension

Fig.9 Multi-wire sawing experimental platform

Fig.10 Measured data of wire tension

Fig.11 Comparison between simulated and measured wire tension

Table.2 Comparison of simulated and measured data for wire tension

切割线	仿真均值/N	仿真标准差/N	实验均值/N	实验标准差/N	决定系数R²	均方根误差/N	相关系数r
F₁	29.399	1.948	29.618	1.441	0.511	1.006	0.715
F₅	12.572	3.131	12.486	4.285	0.891	1.408	0.944
F₉	18.961	3.357	19.054	4.258	0.801	1.896	0.895
F₁₃	26.392	1.358	26.363	1.334	0.617	0.825	0.785

Fig.12 Dynamic characteristics of wire tension under different wire speeds

Fig.13 Dynamic characteristics of wire tension under different main roller accelerations

Fig.14 Dynamic characteristics of wire tension under different main roller radii

Fig.15 Dynamic characteristics of wire tension under different winding/unwinding roller radii

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