Main edge grinding equipment
According to the classification of edge grinding equipment, there are mainly hand-held grinders, belt grinders, and automatic edge grinding machines. The classification of edge grinding effect and quality mainly includes fine grinding, rough grinding, and manual grinding.
Handheld grinder
The hand-held grinder (Figure 2-23) consists of a high-hardness circular grinding disc and a high-speed motor. Through the high-speed rotation of the grinding disc, the diamond on the grinding disc grinds the edge of the glass at high speed to eliminate sharp edges and microcracks.
Advantages: low price, flexible and maneuverable, and can grind the edges of a glass of almost any shape.
Disadvantages: The hand-held grinding force is uneven, the appearance after grinding is uneven, and new microcracks will be generated. The grinding efficiency is low, and it is not suitable for large-scale glass edge grinding.
Advantages: low price, flexible and maneuverable, and can grind the edges of a glass of almost any shape.
Disadvantages: The hand-held grinding force is uneven, the appearance after grinding is uneven, and new microcracks will be generated. The grinding efficiency is low, and it is not suitable for large-scale glass edge grinding.
Belt Sander
The belt grinder (Figure 2-24) consists of a diamond sanding belt and a high-speed motor. The sanding belt’s high-speed movement can eliminate the glass’s sharp edges and micro-cracks. Since the sanding belt has a short service life and cannot correct the uneven cross-section of the glass edge, its appearance is uneven. It has gradually been replaced by automatic edge grinding machines equipped with diamond wheels.
Automatic edge grinding machine
The automatic edge grinding machine mainly comprises a glass conveying and positioning system, a water cooling system, and metal and non-metal grinding wheels containing diamond sand of coarse and refined grains.
Compared with hand-held grinders and belt grinders, the automatic edge grinding machine can grind the edge of the glass through multiple grinding with different grinding wheels, which can almost eliminate the uneven cross-section and micro-cracks on the edge of the glass, and the appearance is very flat and smooth. Depending on the thickness of the glass, the fastest edge grinding speed can exceed 10m/min, and the edge grinding efficiency is greatly improved. It is widely used in large-scale glass deep processing enterprises.
According to the different shapes of the glass, the automatic edge grinding machine mainly includes linear single-sided edge grinding machine, linear double-sided edge grinding machine, special-shaped edge grinding machine, and CNC machining center.
Compared with hand-held grinders and belt grinders, the automatic edge grinding machine can grind the edge of the glass through multiple grinding with different grinding wheels, which can almost eliminate the uneven cross-section and micro-cracks on the edge of the glass, and the appearance is very flat and smooth. Depending on the thickness of the glass, the fastest edge grinding speed can exceed 10m/min, and the edge grinding efficiency is greatly improved. It is widely used in large-scale glass deep processing enterprises.
According to the different shapes of the glass, the automatic edge grinding machine mainly includes linear single-sided edge grinding machine, linear double-sided edge grinding machine, special-shaped edge grinding machine, and CNC machining center.
(1) Vertical linear single-sided edge grinding machine
As shown in Figure 2-25, the vertical linear single-piece edge grinding machine mainly processes the straight edge of the glass. The shape of the edge can be processed into various shapes such as flat edge, bevel edge, round edge, and wavy edge.
This machine can grind the straight edges of any shape of glass. The equipment is inexpensive, occupies a small area, and has good grinding quality. It is widely used in the grinding of architectural glass and furniture glass.
① Machine structure
A vertical linear single-edge grinding machine is generally composed of a base, grinding head, glass transmission mechanism, glass clamping chain plate (front and rear clamping beams), distribution box, water supply and cooling system, etc.
The grinding head part is the core of the machine. They are installed under the front and rear clamping chain plates, and a motor drives each grinding head. When the clamping chain plate transports the glass to the top of the grinding wheel, use the hand wheel to adjust so that the upper surface of the grinding wheel contacts the glass, exits the glass, and re-enters the glass. When entering the glass, observe the grinding head motor ammeter to adjust the grinding wheel grinding amount roughly. When starting the machine, turn on the grinding wheel motor first, then turn on the transmission; otherwise, the glass will break. According to the configuration of the grinding head, the grinding amount of the No. 1 diamond wheel (grit size 80-120) can reach up to 3mm, the grinding amount of the No. 2 diamond wheel (grit size 120-170) is 0.2-0.5mm, and the grinding amount of the No. 3 diamond wheel (grit size 210-270) is about 0.1mm.
The polishing wheel is mainly used to eliminate the grinding marks of the diamond wheel and try to achieve the effect of the original color of the glass. The last polishing is done with a wool felt wheel to increase the glass polishing effect. The wool felt wheel is pneumatically controlled to ensure that the felt wheel always acts on the glass with a certain pressure to ensure the polishing effect. When the glass is transported to the upper edge of the wool felt wheel, the glass hits a connecting rod device, the connecting rod device swings, and presses the stroke switch of the control cylinder solenoid valve. The stroke switch is closed, the solenoid valve is activated, and the cylinder rises against the polishing motor and presses tightly on the edge of the glass. The polishing wheel polishes the glass at a speed of 1500r/min. When polishing with wool felt wheels, polishing liquid must be used. The polishing liquid is a mixture of cerium oxide and water.
Each grinding wheel has a cooling water spray pipe, which supplies water while the grinding wheel rotates to reduce the high temperature generated when the glass is edged.
The vertical linear single-edge grinding machine’s front and rear clamping beams adopt a box beam structure with greater rigidity. The front and rear beam guide rail system adopts end-round guide rails and high wear-resistant steel quenching rails on both sides. The front and rear clamping chain plates are U-shaped and rotate synchronously on the front and rear beams. The glass moves linearly with the clamping chain plates in the front and rear clamping chain plates. The distance between the front and rear clamping chain plates is adjusted to clamp the glass. It can withstand a single piece of glass of about 200kg.
Synchronous belts drive the vertical linear edge grinding machine’s output and input guide rails, and the glass runs synchronously with the synchronous belt. The machine can adjust the front clamping beam according to the thickness of the glass, and the front beam synchronization mechanism completes the movement of the front clamping beam. The digital display can display the moving distance of the front beam. When adjusting, the left and right ends of the front beam must clamp the glass similarly.
Two grinding wheels, one for grinding and the other for polishing, complete the front and rear chamfers of the vertical linear edge grinder. The grinding wheel and the glass plane form a 45° angle.
① Machine structure
A vertical linear single-edge grinding machine is generally composed of a base, grinding head, glass transmission mechanism, glass clamping chain plate (front and rear clamping beams), distribution box, water supply and cooling system, etc.
The grinding head part is the core of the machine. They are installed under the front and rear clamping chain plates, and a motor drives each grinding head. When the clamping chain plate transports the glass to the top of the grinding wheel, use the hand wheel to adjust so that the upper surface of the grinding wheel contacts the glass, exits the glass, and re-enters the glass. When entering the glass, observe the grinding head motor ammeter to adjust the grinding wheel grinding amount roughly. When starting the machine, turn on the grinding wheel motor first, then turn on the transmission; otherwise, the glass will break. According to the configuration of the grinding head, the grinding amount of the No. 1 diamond wheel (grit size 80-120) can reach up to 3mm, the grinding amount of the No. 2 diamond wheel (grit size 120-170) is 0.2-0.5mm, and the grinding amount of the No. 3 diamond wheel (grit size 210-270) is about 0.1mm.
The polishing wheel is mainly used to eliminate the grinding marks of the diamond wheel and try to achieve the effect of the original color of the glass. The last polishing is done with a wool felt wheel to increase the glass polishing effect. The wool felt wheel is pneumatically controlled to ensure that the felt wheel always acts on the glass with a certain pressure to ensure the polishing effect. When the glass is transported to the upper edge of the wool felt wheel, the glass hits a connecting rod device, the connecting rod device swings, and presses the stroke switch of the control cylinder solenoid valve. The stroke switch is closed, the solenoid valve is activated, and the cylinder rises against the polishing motor and presses tightly on the edge of the glass. The polishing wheel polishes the glass at a speed of 1500r/min. When polishing with wool felt wheels, polishing liquid must be used. The polishing liquid is a mixture of cerium oxide and water.
Each grinding wheel has a cooling water spray pipe, which supplies water while the grinding wheel rotates to reduce the high temperature generated when the glass is edged.
The vertical linear single-edge grinding machine’s front and rear clamping beams adopt a box beam structure with greater rigidity. The front and rear beam guide rail system adopts end-round guide rails and high wear-resistant steel quenching rails on both sides. The front and rear clamping chain plates are U-shaped and rotate synchronously on the front and rear beams. The glass moves linearly with the clamping chain plates in the front and rear clamping chain plates. The distance between the front and rear clamping chain plates is adjusted to clamp the glass. It can withstand a single piece of glass of about 200kg.
Synchronous belts drive the vertical linear edge grinding machine’s output and input guide rails, and the glass runs synchronously with the synchronous belt. The machine can adjust the front clamping beam according to the thickness of the glass, and the front beam synchronization mechanism completes the movement of the front clamping beam. The digital display can display the moving distance of the front beam. When adjusting, the left and right ends of the front beam must clamp the glass similarly.
Two grinding wheels, one for grinding and the other for polishing, complete the front and rear chamfers of the vertical linear edge grinder. The grinding wheel and the glass plane form a 45° angle.
② Common grinding faults and treatment of vertical linear edge grinders
a. Glass sintering, polishing is not bright, there is insufficient water spray, the polishing wheel is improperly adjusted, the grinding wheel pressure is insufficient, and the grinding speed is too fast. The treatment measures are to check the water spray system, select an appropriate polishing wheel, increase the grinding wheel pressure, and reduce the grinding speed.
b. The edge and corner are damaged, the diamond wheel grinding volume is too large, the grinding speed is too fast, and the input and output belts are uneven. Treatment measures: reduce the diamond wheel grinding volume, reduce the grinding speed, readjust the polishing wheel, and adjust the horizontal speed of the input and output belts.
c. There are many grinding marks, the grinding speed is too fast, and the water spray is insufficient. Treatment measures: reduce the grinding speed, check the water spray system, and repair the water spray system.
a. Glass sintering, polishing is not bright, there is insufficient water spray, the polishing wheel is improperly adjusted, the grinding wheel pressure is insufficient, and the grinding speed is too fast. The treatment measures are to check the water spray system, select an appropriate polishing wheel, increase the grinding wheel pressure, and reduce the grinding speed.
b. The edge and corner are damaged, the diamond wheel grinding volume is too large, the grinding speed is too fast, and the input and output belts are uneven. Treatment measures: reduce the diamond wheel grinding volume, reduce the grinding speed, readjust the polishing wheel, and adjust the horizontal speed of the input and output belts.
c. There are many grinding marks, the grinding speed is too fast, and the water spray is insufficient. Treatment measures: reduce the grinding speed, check the water spray system, and repair the water spray system.
③ Main specifications of vertical linear edge grinders
: a. Processing glass thickness: 3~30mm.
b. Minimum size of processed glass: 25mm×25mm.
c. Fastest grinding speed: 6m/min.
(2) Special-shaped edge grinding machine
The single-arm special-shaped edge grinding machine (Figure 2-26) can grind the edges of glass of any shape. It is generally composed of a base, a large and small arm, a suction cup (five-star plate), a column, a grinding head, a vacuum component, etc. The suction cup is fixed on the five-star plate, driven by a reducer installed under the base. To ensure the smooth operation of the five-star plate and eliminate the gap, a set of brake devices is installed on the five-star plate spindle transmission gear part. When the machine is stopped, the five-star plate is rotated with about 50kgf (1kgf=9.8N) to ensure no rotation gap in the five-star plate. The glass is placed on the suction cup, and the vacuum is turned on to make the suction cup suck the glass. This way, the glass will not shake in the opposite direction when grinding the glass. The large arm can rotate 360° around the column, the small arm can rotate about 300° around the large arm, and the grinding head can be swung 45° on the horn rack so that the 45° bevel can be ground.
When processing glass or grinding round glass, turn the five-star plate, fix the big and small arms, adjust the grinding wheel position with the adjusting hand wheel, put it on the horn rack to the required angle, turn on the water spray pipe to grind the edge automatically; when processing special-shaped glass, fix the glass, adjust the grinding wheel position, turn on the water spray pipe, do not turn the five-star plate, and push the grinding wheel head by hand for processing.
The single-arm spec,ial-shaped edge grinding machine can grind flat edges, semi-circular edges, round edges, wave bevel edges, and bevel edges.
When processing glass or grinding round glass, turn the five-star plate, fix the big and small arms, adjust the grinding wheel position with the adjusting hand wheel, put it on the horn rack to the required angle, turn on the water spray pipe to grind the edge automatically; when processing special-shaped glass, fix the glass, adjust the grinding wheel position, turn on the water spray pipe, do not turn the five-star plate, and push the grinding wheel head by hand for processing.
The single-arm spec,ial-shaped edge grinding machine can grind flat edges, semi-circular edges, round edges, wave bevel edges, and bevel edges.
(3) Horizontal double-sided linear edge grinding machine
Figure 2-27 is a horizontal double-sided linear edge grinder. It consists of an electrical control console, a machine base, a water tank, a fixed edge (fixed bridge), a mobile working edge (mobile bridge), an inlet support frame, an outlet support frame, a glass conveyor device, a grinding head device, etc.
When a horizontal double-sided linear edge grinder is used to process large-sized glass, two-edge grinders and a steering conveyor are often used as a set. The two-edge grinders are usually arranged at 90°. When the working position is limited, the two-edge grinders and a steering conveyor can also be placed in a straight line. After the glass has finished processing two edges on the first machine, it turns on the steering conveyor and is directly fed to the next machine for double-sided grinding.
A double-sided linear edge grinding machine can only grind rectangular glass, but because it can grind two opposite straight edges of the glass at the same time, the production efficiency is very high, and the grinding error can be less than 0.2mm, which is widely used in large-scale glass deep processing enterprises.
When a horizontal double-sided linear edge grinder is used to process large-sized glass, two-edge grinders and a steering conveyor are often used as a set. The two-edge grinders are usually arranged at 90°. When the working position is limited, the two-edge grinders and a steering conveyor can also be placed in a straight line. After the glass has finished processing two edges on the first machine, it turns on the steering conveyor and is directly fed to the next machine for double-sided grinding.
A double-sided linear edge grinding machine can only grind rectangular glass, but because it can grind two opposite straight edges of the glass at the same time, the production efficiency is very high, and the grinding error can be less than 0.2mm, which is widely used in large-scale glass deep processing enterprises.
Figure 2-27 Horizontal double-sided linear edge grinding machine
① Double-sided grinding wheel configuration
a. Grinding bottom edge grinding wheel. No. 1 diamond wheel, 80-120; No. 2 diamond wheel, 140-170; No. 3 diamond wheel, 210-270; No. 4 polishing wheel, 40; No. 5 polishing wheel, 60; No. 6 polishing wheel, cerium oxide.
a. Grinding bottom edge grinding wheel. No. 1 diamond wheel, 80-120; No. 2 diamond wheel, 140-170; No. 3 diamond wheel, 210-270; No. 4 polishing wheel, 40; No. 5 polishing wheel, 60; No. 6 polishing wheel, cerium oxide.
b. Chamfering Upper and lower chamfering diamond wheel, 325; upper and lower chamfering polishing wheel, 60.
② Horizontal double-sided linear edge grinding machine operation steps
a. Enter the relevant parameters on the control panel computer according to the glass width and thickness, and then press the start button. The machine’s moving edge automatically adjusts to the corresponding width, and the glass presser adjusts to the corresponding height according to the glass thickness.
b. Put the glass on the entrance support frame.
c. Start the grinding wheel, turn on the cooling system simultaneously, and check whether the air pressure value is normal.
d. Turn on the transmission and adjust the grinding speed according to the glass thickness and grinding amount. e. Glass is processed in the working area.
f. Put in glass continuously, and the processed glass is sent to the following process.
③ Working pressure configuration
According to the glass’s thickness and the grinding wheel’s speed, each polishing wheel’s pressure is correctly distributed to obtain satisfactory grinding and polishing effects.
④ Equipment debugging
a. The size between the moving bridge and the fixed bridge is the final size of the glass processing. The cutting amount is generally determined by the glass thickness, cutting accuracy, and the glass feed speed (conveyor belt speed). The thicker the glass is, the faster the glass feed speed is, and the higher the cutting accuracy is, the smaller the cutting amount is.
b. The upper part of the glass conveyor is movable and must be positioned vertically. When the thickness of the glass changes, adjust the glass presser to apply appropriate pressure. The pressure cannot be too large; otherwise, leaving an indentation on the glass is easy. The pressure cannot be too small; otherwise, the glass cannot be clamped tightly, diagonal errors are likely to occur, and the chamfer widths are different.
c. Diamond grinding wheel adjustment Because the diamond wheel has a large grinding volume, the front end of the wheel is about 0.1mm higher than the rear end when grinding the glass. The grinding volume of each grinding wheel is distributed as follows: the grinding volume of the No. 3 diamond wheel is 0.1mm, the grinding volume of the No. 2 diamond wheel is 0.2~0.5mm, and the grinding volume of the No. 1 diamond wheel is the remaining volume.
d. Polishing wheel adjustment The work of the polishing wheel is controlled by a computer, and the air pressure adjustment of each polishing wheel should be adjusted according to the actual requirements of the machine’s various equipment.
e. Cooling water system: The double-sided grinding machine has a water tank. To save water and grind out high-quality glass, the water tank is replaced every 24 hours of work, and the glass powder in the water tank is cleaned. The replaced water can be reused after sedimentation and filtration. When the cooling water is insufficient, it can easily cause glass sintering, glass breakage, poor polishing, etc. Therefore, it is necessary to frequently check whether coagulants block the nozzle and cannot spray water on the grinding wheel.
f. The main technical parameters of double-sided grinding are different according to the specifications. The thickness of the glass processed by double-sided grinding is 3~19mm;
Minimum width: 200mm;
Maximum width: 4000mm;
Processing speed: 0~10m/min.
c. Diamond grinding wheel adjustment Because the diamond wheel has a large grinding volume, the front end of the wheel is about 0.1mm higher than the rear end when grinding the glass. The grinding volume of each grinding wheel is distributed as follows: the grinding volume of the No. 3 diamond wheel is 0.1mm, the grinding volume of the No. 2 diamond wheel is 0.2~0.5mm, and the grinding volume of the No. 1 diamond wheel is the remaining volume.
d. Polishing wheel adjustment The work of the polishing wheel is controlled by a computer, and the air pressure adjustment of each polishing wheel should be adjusted according to the actual requirements of the machine’s various equipment.
e. Cooling water system: The double-sided grinding machine has a water tank. To save water and grind out high-quality glass, the water tank is replaced every 24 hours of work, and the glass powder in the water tank is cleaned. The replaced water can be reused after sedimentation and filtration. When the cooling water is insufficient, it can easily cause glass sintering, glass breakage, poor polishing, etc. Therefore, it is necessary to frequently check whether coagulants block the nozzle and cannot spray water on the grinding wheel.
f. The main technical parameters of double-sided grinding are different according to the specifications. The thickness of the glass processed by double-sided grinding is 3~19mm;
Minimum width: 200mm;
Maximum width: 4000mm;
Processing speed: 0~10m/min.
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