CN102248235B - Device and method for detecting discharge state in electric spark linear cutting work gap - Google Patents
Device and method for detecting discharge state in electric spark linear cutting work gap Download PDFInfo
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- CN102248235B CN102248235B CN2011101331544A CN201110133154A CN102248235B CN 102248235 B CN102248235 B CN 102248235B CN 2011101331544 A CN2011101331544 A CN 2011101331544A CN 201110133154 A CN201110133154 A CN 201110133154A CN 102248235 B CN102248235 B CN 102248235B
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Abstract
The invention relates to a device and a method for detecting the discharge state in an electric spark linear cutting work gap, and belongs to the technical field of electric spark machining. A differential sampling module of the device is connected with the two poles of an electric spark machine tool through a signal transmission cable; a signal output end of the differential sampling module is connected with a signal input end of a threshold value comparison module; a signal output end of the threshold value comparison module is connected with a signal input end of a photoelectric isolation module; a first signal input end of a complex programmable logic device (CPLD) state distinguishing and processing module is connected with a signal output end of the photoelectric isolation module; and a signal output end of the upper computer is connected with a second signal input end of the CPLD state distinguishing and processing module through a CPLD program downloading cable. The threshold value comparison module compares sampled gap voltage signals with set three threshold values through an integration comparator, and sends the comparison result to the photoelectric isolation module. The device and the method can be used for detecting the pulse discharge state of the gap in the electric spark linear cutting machine tool.
Description
Technical field
The present invention relates to a kind of Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus and method, belong to the spark erosion technique field.
Background technology
Spark machined is to carry out the ablation workpiece material by pulse feature spark discharge between tool-electrode and workpiece, to reach the predetermined processing request of size, shape and surface quality to part.Electric discharge machining method is not subject to the restriction of the mechanical performances such as the material hardness, intensity of workpiece, there is the advantages such as macroscopical cutting force is little simultaneously, therefore be particularly suitable for difficult processing rapidoprint and complex-shaped workpieces processing, have a wide range of applications in fields such as Aeronautics and Astronautics, moulds.
In the edm process of metal material, the voltage across poles signal reaction pulsed discharge situation in the process, efficiency and the precision of this and spark machined are closely related.When pulsed discharge is the spark discharge state, the gap both end voltage is by floating voltage through the time delay that punctures after a while, and gap punctures, and the gap both end voltage drops to electric discharge by floating voltage and maintains voltage.In Wire-cut Electrical Discharge Machining, because there are relative motion in wire electrode and workpiece, it is generally acknowledged and do not have the stable arc electric discharge phenomena.But, in actual process, there are the electric discharge phenomena that do not puncture time delay, the unstable arc discharge condition that this discharge condition is inclined to one side short circuit.It shows now gap chip removal difficulty, and machining state is poor, so, in the Wire-cut Electrical Discharge Machining process, need to and contain the spark discharge state area that punctures time delay by this discharge condition and branch away.Therefore in the Wire-cut Electrical Discharge Machining of metal material, the intermittent pulse discharge state is divided into: zero load, spark discharge, unstable arc electric discharge and short circuit.
Spark erosion technique generally is used for processing conductive material, existing assisting electrode method can realize utilizing spark technology processing insulating ceramics, its principle is in the surface of the work additional conductive layer, utilizes the conducting film formed in discharge process to form auxiliary electrode and realizes electric discharge processing.In the Wire-cut Electrical Discharge Machining process of insulating ceramics, when conducting film forms when poor, now conducting film thickness is little, and resistance is large, gap high-voltage discharge phenomenon occurs.Maintain voltage when gap discharge voltage during higher than processing metal, spark discharge state now is called to high resistant spark state, short-circuit condition now is called the high resistant short-circuit condition.When conducting film forms when good, now conducting film thickness is large, and resistance is little, when gap discharge voltage is approximately equal to processing metal, maintains voltage, and spark discharge state now is called to low-resistance spark state, and short-circuit condition now is called the low-resistance short-circuit condition.Therefore, in the insulating ceramics Wire-cut Electrical Discharge Machining, clearance discharge condition is divided into five kinds, is respectively zero load, high resistant spark, low-resistance spark, high resistant short circuit and low-resistance short-circuit condition.
Current spark coil cutting processor bed, general the average voltage to gap detected, and determines the size of current servo feed speed as reference value.During higher than reference value, accelerate feeding when the gap average voltage, when the gap average voltage, during lower than reference value, the workbench feed-disabling, enter wait, when the short circuit detected reaches some, controls the servo rollback of workbench.This gap state detection method can be similar to the current clearance discharge condition of reflection, but because the gap average voltage is that average voltage by various discharge conditions forms, can not be detected the individual pulse discharge condition, so the average electrical platen press contains uncertain factor, can not realize gap is monitored in real time and accurately, likely can worsen processing effect.Particularly for the insulating ceramics Wire-cut Electrical Discharge Machining, owing to there being the high resistant discharge condition, the average voltage in gap is high, adopts the average voltage detection method can accelerate feed speed, and this will cause the processing effect deterioration even can not process, now the average voltage detection method lost efficacy.
Summary of the invention
The object of the present invention is to provide a kind of electrospark wire-electrode cutting process discharge condition detecting device, this checkout gear is by the gap voltage of each pulse of real-time sampling, by the judgement residing interval of gap voltage and to the detection of gap breakdown signal, when finishing, pulsewidth judges current pulsed discharge state, and the paired pulses status information is carried out statistical disposition, infer the machining state that gap, using this as servo-controlled foundation.
The present invention is achieved by the following technical solutions:
The Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus, comprise the difference sampling module, the threshold value comparison module, photoelectric isolation module, CPLD differentiates and processing module, host computer, the PCI104 bus cable, CPLD program download cable and signal-transmitting cable, the difference sampling module is connected with the two poles of the earth of spark-erosion machine tool by signal-transmitting cable, the signal output part of difference sampling module is connected with the signal input part of threshold value comparison module, the signal output part of threshold value comparison module is connected with the signal input part of photoelectric isolation module, the first signal input of CPLD condition discrimination and processing module is connected with the signal output part of photoelectric isolation module, the signal output part of CPLD condition discrimination and processing module is connected with the signal input part of host computer by the PCI104 bus cable, the signal output part of host computer is connected with the secondary signal input of CPLD condition discrimination and processing module by CPLD program download cable.Described threshold value comparison module compares three threshold values of the gap voltage signal of sampling and setting by integrated comparator, and the result compared is sent into to photoelectric isolation module; The threshold value setting of three comparators of threshold value comparison module is corresponding threshold value V respectively
Ef1, V
Ef2, V
Ef3, in the spark machined of metal material, threshold value V
Ef3Be set as 3～5V, threshold value V
Ef2Be set to be slightly less than the metal pulsed discharge and maintain magnitude of voltage, threshold value V
Ef1Be set to a little less than floating voltage; In the Wire-cut Electrical Discharge Machining of insulating ceramic materials, only need to adjust threshold value V
Ef2Get final product threshold value V
Ef2Be set to be slightly larger than the metal pulsed discharge and maintain magnitude of voltage, V
Ef3Be set to 3V, V
Ef2Be set to 40V, V
Ef1Be set to 70V.
Wire-cut Electrical Discharge Machining clearance discharge condition detection method, comprise the steps:
Utilize integrated operational amplifier to adopt the mode of calculus of differences that the gap voltage signals collecting is arrived to checkout gear, and access threshold value comparison module;
Described threshold value comparison module compares three threshold values of the gap voltage signal of sampling and setting by integrated comparator, and the result compared is sent into to photoelectric isolation module;
Described photoelectric isolation module is sent into CPLD condition discrimination and processing module by comparative result through the photoelectricity isolation by photoelectrical coupler;
Described CPLD condition discrimination and processing module are processed the signal of input, by the detection to gap voltage number with input signal is carried out to logical operation, judge the discharge condition when prepulse, and are sent to host computer by the PCI104 bus cable; At first during pulsewidth, by whether exist trailing edge to come detector gap whether to puncture to input signal, and each input signal is carried out to logical operation, differentiate the pulsed discharge state, then realize carrying out State-output by the controlling of sampling pulse when pulsewidth closes to an end, and utilize state to keep module that status information is remained between arteries and veins and finishes always, realize the differentiation to clearance discharge condition with this;
Described host computer obtains the discharge condition information of each pulse, and carries out statistical disposition, infers the now machining state in gap, for the operation of control system provides foundation.
Beneficial effect of the present invention mainly comprises:
1, checkout gear adopts CPLD to carry out condition discrimination and processing, and CPLD has born main condition discrimination work, and because CPLD is the online programmable module, therefore whole checkout gear has very large flexibility.
2, checkout gear can be realized each pulsed discharge state is differentiated, can obtain more fully gap state information, and clearance discharge condition detection apparatus can be distinguished without the unstable arc discharge condition that punctures time delay, be conducive to judge more accurately current gap machining state, therefore to have real-time good for device, accurately and the advantage such as stablize.
3, checkout gear both can also can be used in the Wire-cut Electrical Discharge Machining of insulating ceramic materials for the Wire-cut Electrical Discharge Machining of metal material, only need can realize by adjusting threshold value, and therefore device has advantages of that operation is convenient and applied widely.
The accompanying drawing explanation:
Fig. 1 is Wire-cut Electrical Discharge Machining pulsed discharge state waveform differentiation figure, wherein: figure is a) metal material Wire-cut Electrical Discharge Machining waveform differentiation figure, metal material is in carrying out edm process, the pulsed discharge state has zero load, spark, unstable arc and short-circuit condition, CMP1, CMP2 and CMP3 are three input signals of CPLD, V
Ef1, V
Ef2, V
Ef3Three threshold values that arrange; Figure b) be insulating ceramics Wire-cut Electrical Discharge Machining waveform differentiation figure, in insulating ceramics Wire-cut Electrical Discharge Machining process, the pulsed discharge state has zero load, high resistant spark, low-resistance spark, high resistant short circuit and low-resistance short-circuit condition, and CMP1, CMP2 and CMP3 are three input signals of CPLD, V
Ef1, V
Ef2And V
Ef3Three threshold values that arrange;
Fig. 2 is the structural representation of Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus, wherein: label 1 means electric spark machine tool, label 2 means signal-transmitting cable, label 3 means the difference sampling module, and label 4 means the threshold value comparison module, and label 5 means photoelectric isolation module, label 6 means CPLD condition discrimination and processing module, label 7 means the PCI104 bus cable, and label 8 means host computer, and label 9 means CPLD program download cable;
Fig. 3 is Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus circuit theory schematic diagram;
Fig. 4 is the CPLD internal circuit program schematic diagram of Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus;
Fig. 5 is the electrical block diagram of CPLD internal circuit program SERVO program block;
Fig. 6 is metal material Wire-cut Electrical Discharge Machining CPLD procedure simulation oscillogram;
Fig. 7 is insulating ceramic materials Wire-cut Electrical Discharge Machining CPLD procedure simulation oscillogram.
The specific embodiment:
Below in conjunction with accompanying drawing, the present invention is described in further detail: the present embodiment is implemented take technical solution of the present invention under prerequisite, provided detailed embodiment and specific operation process, but protection scope of the present invention is not limited to following embodiment.
As shown in Figure 2, the electric spark clearance discharge condition detection apparatus that the present embodiment is related, comprise signal-transmitting cable 2, difference sampling module 3, threshold value comparison module 4, photoelectric isolation module 5, CPLD(CPLD) condition discrimination and processing module 6, PCI104 bus cable 7, host computer 8 and CPLD program download cable 9.Connected mode is as follows: difference sampling module 3 is connected with the two poles of the earth of spark-erosion machine tool 1 by signal-transmitting cable 2, the signal output part of difference sampling module 3 is connected with the signal input part of threshold value comparison module 4, the signal output part of threshold value comparison module 4 is connected with the signal input part of photoelectric isolation module 5, the first signal input of CPLD condition discrimination and processing module 6 is connected with the signal output part of photoelectric isolation module 5, the signal output part of CPLD condition discrimination and processing module 6 is connected with the signal input part of host computer 8 by PCI104 bus cable 7, the signal output part of host computer 8 is connected with the secondary signal input of CPLD condition discrimination and processing module 6 by CPLD program download cable 9.
Its cardinal principle is to be input to the difference sampling module when electric spark machine tool the two poles of the earth gap voltage signal by signal-transmitting cable, the difference sampling module gathers the voltage signal at spark-erosion machine tool the two poles of the earth, and convert thereof into the following voltage signal of checkout gear power supply voltage, the threshold value comparison module compares this voltage signal and set threshold value, obtain current voltage interval of living in, result relatively is in photoelectric isolation module input CPLD, the voltage signal of CPLD real-time tracking input during pulsewidth, whether there is trailing edge according to the residing amplitude interval of voltage signal during pulsewidth and signal, when pulsewidth finishes, judge the discharge condition of this pulse, the result of judgement is sent to the host computer storage via the PCI104 bus, and carry out statistical disposition, for servo-control system provides servo foundation.Stored the internal processes of CPLD on host computer, can download in CPLD via JTAG type CPLD program download cable by the mode of online programming.
The circuit theory diagrams of the electric spark clearance discharge condition detection apparatus that Fig. 3 provides for this specific embodiment, mapping software used is Protel DXP2004.Comprise the difference sampling module, threshold value comparison module, photoelectric isolation module, CPLD condition discrimination and processing module.
Concrete, difference sampling module (U1) is integrated transporting discharging LF357N, inverting input 2 ends of the anodal access U1 that connects with R1, R3 of lathe, the lathe negative pole is connected with R2, R4 and is accessed in-phase input end 3 ends of U1, in analog, output 6 ends of U1 are connected with R7 and are accessed inverting input 2 ends of U1 for in-phase input end 3 ends of U1 and R5 series connection.C9 and C21 parallel connection access afterwards the positive supply input of U1 and in analog between, play the effect of decoupling.C10 and C20 parallel connection access afterwards the negative supply input of U1 and in analog between, play the effect of decoupling.
Threshold value comparison module (U4 and U5) is integrated comparator LM393AN, output 6 ends of U1 are connected with R8 and are accessed inverting input 2 ends of U4A, output 6 ends of U1 are connected with R10 and are accessed inverting input 6 ends of U4B, and output 6 ends of U1 are connected with R14 and accessed inverting input 2 ends of U5A.R9 and potentiometer R23 series connection access+15V and in analog between, output 2 terminations of potentiometer R23 enter in-phase input end 3 ends of U4A.R11 and potentiometer R24 series connection access+15V and in analog between, output 2 terminations of potentiometer R24 enter in-phase input end 5 ends of U4B.R15 and potentiometer R25 series connection access+15V and in analog between, output 2 terminations of potentiometer R25 enter in-phase input end 3 ends of U5A.Output 1 end of U4A and connect+5V after R12 connects, output 7 ends of U4B and connect+5V after R13 connects, output 1 end of U5A and connect+5V after R16 connects.
Photoelectric isolation module (U7, U8 and U9) is high speed photo coupling 6N137, and output 1 end of U4A is connected with R17 and accessed 2 ends of U7, and output 1 end of U5A is connected with R18 and accessed 2 ends of U8, and output 7 ends of U4B are connected with R17 and accessed 2 ends of U9.In analog, in analog, 3 terminations of U9 in analog for 3 terminations of U8 for 3 terminations of U7.The anodal VCC of the 8 termination digital circuit power supplies of U7,5 terminations of U7 digitally, access C13 between 8 ends of U7 and 5 ends, 8 ends of the 6 end series connection R20 access U7 of U7.The anodal VCC of the 8 termination digital circuit power supplies of U8,5 terminations of U8 digitally, access C14 between 8 ends of U8 and 5 ends, 8 ends of the 6 end series connection R21 access U8 of U8.The anodal VCC of the 8 termination digital circuit power supplies of U9,5 terminations of U9 digitally, access C15 between 8 ends of U9 and 5 ends, 8 ends of the 6 end series connection R22 access U9 of U9.
CPLD differentiates and processing module (U6) is EPM7064SLC44-10 type CPLD, and U3 is phase inverter 74AC14B, and U2 is the active crystal oscillator of OSC 25MHz, and P1 is that JTAG downloads terminal, and G1 is exclusion.33 ends of U6 are connected with 6 ends of U7, and 34 ends of U6 are connected with 6 ends of U8, and 36 ends of U6 are connected with 6 ends of U9, and 37 ends of U6 are connected with outside pulsewidth end signal.16 ends of U6,17 ends, 18 ends, 19 ends and 20 ends are output, with the PCI104 bus, are connected.10 ends of U6,22 ends, 30 ends and 42 terminations digitally, 3 ends of U6,15 ends, 23 ends and 35 termination power VCC.1 end of P1 is connected with 32 ends of U6, and 3 ends of P1 are connected with 38 ends of U6, and 5 ends of P1 are connected with 13 ends of U6, and 7 ends of P1 are connected with 7 ends of U6 with 9 ends, 2 ends of P1 and 10 terminations digitally, the 4 termination VCC of P1.2 terminations of U2 digitally, 1 end of the 3 termination U3A of U2, the 4 termination VCC of U2.43 ends of the 2 termination U6 of U3A.
The CPLD internal circuit programme diagram of the electric spark clearance discharge condition detection apparatus that Fig. 4 provides for this specific embodiment, program development software (PDS) used is Quartus II 7.0.43 ends that input CLK is chip U6,37 ends that input End_pulse is chip, 33 ends that input CMP1 is U6,34 ends that input CMP2 is U6,36 ends that input CMP3 is U6.19 ends that output Spark/Spark_H is U6,18 ends that output Spark_L is U6,20 ends that output Open is U6,17 ends that output Arc/Short_H is U6,16 ends that output Short/Short_L is U6.
CPLD internal circuit program package, containing four module, is respectively the gap breakdown detection module, logic judgment module, and state controlling of sampling module and state keep module.
Concrete, for the gap breakdown detection module: can see from the spark machined discharge condition waveform differentiation figure shown in Fig. 1, when punch-through occurs in gap, there are trailing edge in CMP1 or CMP2 between CMP 3 high period, therefore can, between the CMP3 high period, by the detection to CMP1 and CMP2 trailing edge, realize the detection to the gap breakdown signal.The gap breakdown detection module comprises two parts, is respectively CMP1 trailing edge detection module DFF register Inst33 and CMP2 trailing edge detection module DFF register Inst1.PUL1 output is low level always, and when input, there is trailing edge in CMP1 between the CMP3 high period, and PUL1 output high level also remains to the pulsewidth end always.PUL2 output is low level always, and when input, there is trailing edge in CMP2 between the CMP3 high period, and PUL2 output high level also remains to the pulsewidth end always.Utilize the reset signal of CMP3 as two registers, between the CMP3 low period, between arteries and veins during, the zero clearing of gap breakdown detection module, wait for next pulsewidth.
Logic judgment module: two inputs form the logic judgment module between the CMP3 high period with door Inst5, Inst6, Inst11, three value and gate Inst13, Inst14, Inst15 and not gate Inst8, Inst10, Inst12, Inst16.
State controlling of sampling module: not gate Inst34, the SELECT_PUL program block, DFF register Inst2 and two inputs form state controlling of sampling module with door Inst19, an Inst20, Inst21, Inst22, Inst23, and End_Pulse is the state sampling control signal of pulsewidth while closing to an end.Because the gap voltage signal enters checkout gear from signal-transmitting cable, through the difference sampling, comparing element, the photoelectricity isolation processing enters CPLD, by producing the overall transfer time delay of 1-2 μ s, therefore can utilize the master of power supply to shake signal as the End_Pulse signal.When there is trailing edge in the End_Pulse signal, show now to start the output of PUL1, PUL2, Inst13, Inst5 and Inst6 of sampling, and sampled result is kept to 0.8 μ s.It is 0.8 μ s that the SELECT_PUL program block is used for arranging sampling pulse length, the rising edge that wherein SLE_PUL is sampling pulse, and the end signal that END_PUL is sampling pulse, by these two signal input DFF registers, just obtained the sampling pulse of 0.8 μ s.Output by five two inputs with door sampling PUL1, PUL2, Inst13, Inst5 and Inst6.
State keeps module: 5 road SERVO program block formation states keep module, and for 5 tunnel outputs of hold mode controlling of sampling module, Fig. 5 is the circuit structure diagram of SERVO program block.The output of state controlling of sampling module samples De Ge road is as status information, and transmission enters the SERVO program block, utilizes DFF register Inst1 to be kept, and remains to next pulsewidth arriving always.DFF register Inst is used to provide reset signal, and ENABLE is connected with outside CMP3, when next pulsewidth, comes temporarily, and from low to high, the preceding state sample information is eliminated the ENABLE signal.2us_CON is used for removing reset signal at sampling control signal temporarily, prepares to carry out the state maintenance.The output of 5 road SERVO, at each impulse duration, only have the output that this pulsed discharge state is corresponding to have high level, and all the other four tunnel outputs are low always, have so just realized differentiation pulsed discharge state.In the spark machined of metal, the corresponding spark State-output of output Spark/Spark_H, Spark_L is meaningless in output, the corresponding Light Condition output of output Open, the corresponding unstable arc State-output of output Arc/Short_H, the corresponding short-circuit condition output of output Short/Short_L.In the Wire-cut Electrical Discharge Machining of insulating ceramics, the corresponding high resistant spark of output Spark/Spark_H State-output, the corresponding low-resistance spark of output Spark_L State-output, the corresponding Light Condition output of output Open, the corresponding high resistant short-circuit condition output of output Arc/Short_H, the corresponding low-resistance short-circuit condition output of output Short/Short_L.
Process electric spark clearance discharge condition detected below by specific embodiment is described further:
The Wire-cut Electrical Discharge Machining of embodiment 1 metal material
Hardware circuit and CPLD internal circuit, as described in Fig. 2-5, only need to adjust V
Ef1, V
Ef2, V
Ef3Three threshold values get final product.Corresponding Threshold value is relative floating voltage, and the threshold value setting of three comparators of threshold value comparison module is corresponding threshold value V respectively
Ef1, V
Ef2, V
Ef3, but its value equals V
Ef1, V
Ef2, V
Ef3Be multiplied by the sampling ratio of difference sampling module.Threshold value V
Ef3Be set as 3～5V, its effect is to distinguish between the pulsewidth and arteries and veins of each pulse, controls trace routine and only during pulsewidth, discharge condition is differentiated, and during between arteries and veins, does not differentiate state, prevents that erroneous judgement is disconnected.Threshold value V
Ef2Be set to be slightly less than the metal pulsed discharge and maintain magnitude of voltage, threshold value V
Ef1Be set to a little less than floating voltage.In the spark machined of metal material, V
Ef3Be set to 3V, V
Ef2Be set to 18V.V
Ef1Be set to 70V.
Gap voltage enters the threshold value comparison module through the difference sampling module, with the threshold value set, compares, after the photoelectricity isolation, CMP1, CMP2, the waveform of CMP3 signal, and the output of CPLD internal breakdown signal detection module Inst1 and Inst33, as Fig. 1 a) as shown in.
Between the CMP3 high period, namely, during pulsewidth, different clearance discharge conditions has different CMP1 and CMP2 signal.During pulsewidth, if there is trailing edge in CMP1, show gap voltage from high to low, punch-through occurs, and there is not trailing edge in CMP2, after gap voltage punctures higher than V
Ef2, this pulsed discharge is the spark state, and Inst33 exports high level, and after controlling of sampling finishes, output Spark/Spark_H is high level, and all the other are output as low level.During pulsewidth, when there are not trailing edge in CMP1 and CMP2, need minute following three kinds of situations.At first, if CMP1 is output as high level, show that the gap both end voltage is higher than V
Ef1, this pulsed discharge is Light Condition, and Inst13 exports high level, and after controlling of sampling finishes, output Open is high level, and all the other are output as low level; Secondly, if CMP1 is low level, and CMP2 is high level, shows that now the gap both end voltage is always at V
Ef1And V
Ef2Between, and don't have gap breakdown, and this pulsed discharge is the unstable arc state, and Inst4 exports high level, and after controlling of sampling finishes, output Arc/Short_H is high level, and all the other are output as low level.Finally, if CMP2 is low level always, show that now the gap both end voltage is always lower than V
Ef2, and do not have gap breakdown yet, and thinking that this pulsed discharge is short-circuit condition, Inst15 exports high level, and after controlling of sampling finishes, output Short/Short_L is high level, and all the other are output as low level.Just realized thus the condition discrimination to arbitrary pulsed discharge, the differentiation result is via the PCI104 bus transfer to host computer, and host computer, according to the discharge condition information of each pulse, is inferred gap machining state now.Fig. 7 metal material spark machined CPLD procedure simulation oscillogram.According to Fig. 1 a) in CMP1, CMP2 and CMP3 set the input signal of CPLD, utilize the Simulator module of Quartus program to carry out emulation to the CPLD program, from simulation result, can find out, system can be differentiated the discharge condition of each pulse, and status information remains to next pulse always.
The Wire-cut Electrical Discharge Machining of embodiment 2 insulating ceramic materials
Hardware circuit and CPLD internal circuit, as described in Fig. 2-5, only need to adjust threshold value V
Ef2Get final product.Threshold value V
Ef2Be set to be slightly larger than the metal pulsed discharge and maintain magnitude of voltage, so in the Wire-cut Electrical Discharge Machining of insulating ceramics, V
Ef3Be set to 3V, V
Ef2Be set to 40V.V
Ef1Be set to 70V.
Gap voltage enters the threshold value comparison module through the difference sampling module, with the threshold value set, compares, after the photoelectricity isolation, CMP1, CMP2, the waveform of CMP3 signal, and the output of CPLD internal breakdown signal detection module Inst1 and Inst33, as Fig. 1 b) as shown in.
Between the CMP3 high period, namely, during pulsewidth, different clearance discharge conditions has different CMP1 and CMP2 signal.During pulsewidth, if there is trailing edge in the output of CMP1 and CMP2, show gap voltage from high to low, punch-through occurs, and punctures post gap voltage lower than V
Ef2, this pulsed discharge is low-resistance spark state, and Inst1 exports high level, and after controlling of sampling finishes, output Spark_L is high level, and all the other are output as low level.During pulsewidth, when there is not trailing edge in CMP2, there is trailing edge in CMP1 output, although show that gap has occurred to puncture, gap discharge voltage is higher than V
Ef2And lower than V
Ef1, assert that this pulsed discharge is high resistant spark state, Inst33 exports high level, and after controlling of sampling finishes, output Spark/Spark_H is high level, and all the other are output as low level.When there are not trailing edge in CMP1 during pulsewidth and CMP2, need minute following three kinds of situations.At first, if CMP1 is output as high level, show that the gap both end voltage is higher than V
Ef1, thinking that this pulsed discharge is Light Condition, Inst13 exports high level, and after controlling of sampling finishes, output Open is high level, and all the other are output as low level; Secondly, if CMP1 is low level, and CMP2 is high level, shows that now the gap both end voltage is always at V
Ef1And V
Ef2Between, and don't have gap breakdown, and therefore thinking that this pulsed discharge is the high resistant short-circuit condition, Inst4 exports high level, and after controlling of sampling finishes, output Arc/Short_H is high level, and all the other are output as low level.Finally, if CMP2 is low level always, show that now the gap both end voltage is always lower than V
Ef2, and do not have gap breakdown yet, and thinking that this pulsed discharge is the low-resistance short-circuit condition, Inst15 exports high level, and after controlling of sampling finishes, output Short/Short_L is high level, and all the other are output as low level.Just realized thus the condition discrimination to arbitrary pulsed discharge, the differentiation result is via the PCI104 bus transfer to host computer, and host computer, according to the discharge condition information of each pulse, is inferred gap machining state now.Fig. 8 is insulating ceramic materials Wire-cut Electrical Discharge Machining CPLD procedure simulation oscillogram.According to Fig. 1 b) in CMP1, CMP2 and CMP3 set the input signal of CPLD, utilize the Simulator module of Quartus program to carry out emulation to the CPLD program, from simulation result, can find out, system can be differentiated the discharge condition of each pulse, and status information remains to next pulse always.
The above; it is only the preferably specific embodiment of the present invention; these specific embodiment all are based on the different implementations under general idea of the present invention; and protection scope of the present invention is not limited to this; anyly be familiar with those skilled in the art in the technical scope that the present invention discloses; the variation that can expect easily or replacement, within all should being encompassed in protection scope of the present invention.Therefore, protection scope of the present invention should be as the criterion with the protection domain of claims.
Claims (5)
1. a Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus, it is characterized in that, comprise the difference sampling module, the threshold value comparison module, photoelectric isolation module, CPLD condition discrimination and processing module, host computer, the PCI104 bus cable, CPLD program download cable and signal-transmitting cable, the difference sampling module is connected with the two poles of the earth of spark-erosion machine tool by signal-transmitting cable, the signal output part of difference sampling module is connected with the signal input part of threshold value comparison module, the signal output part of threshold value comparison module is connected with the signal input part of photoelectric isolation module, the first signal input of CPLD condition discrimination and processing module is connected with the signal output part of photoelectric isolation module, the signal output part of CPLD condition discrimination and processing module is connected with the signal input part of host computer by the PCI104 bus cable, the signal output part of host computer is connected with the secondary signal input of CPLD condition discrimination and processing module by CPLD program download cable, described threshold value comparison module compares three threshold values of the gap voltage signal of sampling and setting by integrated comparator, and the result compared is sent into to photoelectric isolation module, the threshold value setting of three comparators of threshold value comparison module is corresponding threshold value V respectively
ef1, V
ef2, V
ef3, in the spark machined of metal material, threshold value V
ef3be set as 3～5V, threshold value V
ef2be set to be slightly less than the metal pulsed discharge and maintain magnitude of voltage, threshold value V
ef1be set to a little less than floating voltage, in the Wire-cut Electrical Discharge Machining of insulating ceramic materials, only need to adjust threshold value V
ef2get final product threshold value V
ef2be set to be slightly larger than the metal pulsed discharge and maintain magnitude of voltage.
2. Wire-cut Electrical Discharge Machining clearance discharge condition detection apparatus according to claim 1, it is characterized in that, described difference sampling module is the integrated operational amplifier module that bandwidth 5MHz is above and voltage conversioning rate is 50V/ μ s, described threshold value comparison module is the high speed analog comparator module that reaches nanosecond time delay, and described photoelectric isolation module is the photoelectric coupler module that bandwidth 1MHz is above and voltage conversioning rate is 500V/ μ s.
3. a Wire-cut Electrical Discharge Machining clearance discharge condition detection method, is characterized in that, comprises the steps:
Utilize integrated operational amplifier to adopt the mode of calculus of differences that the gap voltage signals collecting is arrived to checkout gear, and access threshold value comparison module;
Described threshold value comparison module compares three threshold values of the gap voltage signal of sampling and setting by integrated comparator, and the result compared is sent into to photoelectric isolation module;
Described photoelectric isolation module is sent into CPLD condition discrimination and processing module by comparative result through the photoelectricity isolation by photoelectrical coupler;
Described CPLD condition discrimination and processing module are processed the signal of input, by the detection to the gap voltage signal with to input signal, carry out logical operation, judge the discharge condition when prepulse, and are sent to host computer by the PCI104 bus cable; At first during pulsewidth, by whether exist trailing edge to come detector gap whether to puncture to input signal, and each input signal is carried out to logical operation, differentiate the pulsed discharge state, then realize carrying out State-output by the controlling of sampling pulse when pulsewidth closes to an end, and utilize state to keep module that status information is remained between arteries and veins and finishes always, realize the differentiation to clearance discharge condition with this;
Described host computer obtains the discharge condition information of each pulse, and carries out statistical disposition, infers the now machining state in gap, for the operation of control system provides foundation.
4. Wire-cut Electrical Discharge Machining clearance discharge condition detection method according to claim 3, it is characterized in that, the sample mode of described gap voltage is the calculus of differences mode, and corresponding sampling A/D chip is integrated operational amplifier and has the above bandwidth of 5M and the voltage conversioning rate of 50V/ μ s.
5. Wire-cut Electrical Discharge Machining clearance discharge condition detection method according to claim 3, is characterized in that, the photoelectrical coupler of described photoelectric isolation module has the above frequency response of 1MHz and the voltage conversioning rate of 500V/ μ s.
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| CN102626810B (en) * | 2012-05-02 | 2013-12-04 | 宣浩 | Vibration discharge processing method |
| CN102886574A (en) * | 2012-07-05 | 2013-01-23 | 宁波虎兴数控科技有限公司 | Novel sampling circuit for linear cutting |
| CN103624344A (en) * | 2013-12-16 | 2014-03-12 | 贵州航中力电精机科技有限公司 | Control system of electric discharge machining unit |
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| CN106513877B (en) * | 2016-10-18 | 2018-05-01 | 丁毅 | A kind of control method of electric pulse spark-discharge gap |
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| CN107891199B (en) * | 2017-12-01 | 2019-02-15 | 中州大学 | Spark discharge condition checkout gear and recognition methods |
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| EP3711886A1 (en) * | 2019-03-22 | 2020-09-23 | Agie Charmilles SA | Wire electrical discharge machining method |
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| CN110548941A (en) * | 2019-10-16 | 2019-12-10 | 江苏冬庆数控机床有限公司 | detection device and detection method for discharge state of wire cut electrical discharge machining |
| CN111121612B (en) * | 2020-01-02 | 2021-08-24 | 北方工业大学 | Method for identifying surface scratch depth of cadmium disc of spark test device |
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| CN101259551B (en) * | 2008-04-08 | 2010-10-06 | 哈尔滨工业大学 | Electrospark wire-electrode cutting process discharge condition detecting device |
| CN101318241B (en) * | 2008-04-08 | 2010-04-07 | 哈尔滨工业大学 | Impulsing power source for spark pinhole processing |
| CN101474698B (en) * | 2009-01-08 | 2010-06-30 | 上海交通大学 | Millicrosecond grade micro-energy impulsing power source based on FPGA |
| CN201735916U (en) * | 2010-03-08 | 2011-02-09 | 苏州新火花机床有限公司 | Multi-mode real-time sampling digital servo feed system for medium-speed wire-cutting machine |
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