CN102909447A - Electric spark servo control method based on current pulse probability detection - Google Patents
Electric spark servo control method based on current pulse probability detection Download PDFInfo
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Abstract
An electric spark servo control method based on current pulse probability detection is characterized in that a current signal is adopted as a sampled signal; the current pulse occurring probability in a sampling period is acquired through a sampling circuit, so as to obtain a sampled current pulse probability; the sampled current pulse probability is calculated and stored by adopting a microprocessor, and is compared with a set current pulse probability, so as to obtain a scaling factor serving as servo control reference and control the feeding of an electric spark machine tool; when the sampled current pulse probability is larger than the set current pulse probability, the present feeding speed is multiplied by the scaling factor; and when the sampled current pulse probability is smaller than the set current pulse probability, the present feeding speed is multiplied by the scaling factor, so that the practical current pulse probability gets is changed to be equal to the set current pulse probability step by step. The method has the advantages that the controlling precision is high, the phenomena of over feeding and lack of feeding can be avoided; suitability for various electric spark processing forms of metal, semi-conductors, and heterogeneous composite materials containing conductive substances is realized; and the processing stability and the processing quality can be improved.
Description
Technical field
The present invention relates to a kind of spark erosion technique, especially a kind of control method of Electrode in EDM feed speed, specifically a kind of electric spark method of servo-controlling based on the current impulse Probability Detection that is applicable to metal, semi-conducting material and contains the heterogeneous body composite spark machined of conductive materials.
Background technology
Spark machined is a kind of special process method of the high temperature galvanic action ablation material that produces when utilizing two interpolar pulsed discharges.It mainly contains following characteristics:
1. can process material and complex-shaped workpieces that the conventional machining processes method is difficult to cut;
2. add man-hour without macroscopical cutting force;
3. do not produce the defectives such as burr and tool marks rill;
4. the tool-electrode material need not harder than workpiece material.
For keeping normal spark discharge, must make has certain discharging gap between workpiece and electrode, carries out automatic servo feed by detecting workpiece and interelectrode spacing size.Existing traditional method of servo-controlling mainly is the size that indirectly reflects the gap by workpiece and interelectrode average voltage size, and main method has average voltage detection method and crest voltage detection method.
The average voltage detection method is exactly to utilize to add average voltage and the set reference voltage in man-hour and compare, thereby whether decision carries out servo feed.By the current-voltage characteristic of three kinds of discharge conditions of Fig. 1 metal material spark machined as can be known, its voltage characteristic has obvious difference under unloaded, regular picture and short-circuit condition.Adding man-hour, if the floating voltage pulse is more, its interpolar average voltage then can increase; If the short-circuit voltage pulse is more, then the interpolar average voltage will reduce.When the interpolar average voltage is higher than reference voltage, illustrate that discharging gap is in and owes tracking mode greater than desirable discharging gap at this moment, should increase feed speed; When average voltage is lower than reference voltage, illustrate that discharging gap was in tracking mode less than desirable discharging gap at this moment, should reduce feed speed; When average voltage is close with reference voltage, illustrate that this moment, discharging gap was more satisfactory discharging gap, then keep current electrode feed speed.Work in-process can reach desirable feed speed by adjusting servo feed.
But there is limitation in existing method of servo-controlling, needs man-hour the various parameters of manual adjustment reach desirable feed speed adding.Reponse system can only be carried out servo adjusting in the scope that sets, can't reach automatically best feed speed, so depend on to a great extent operating personnel's experience.
Development along with science and technology, semi-conducting material is used increasingly extensive in every profession and trade, but semiconductor belongs to typical hard crisp shaped material, its height that enbrittles, fracture toughness is low, the characteristics such as elastic limit of materials and intensity approach very much, traditional machining process is very difficult when running into high thickness, non-rectilinear machined surface.Spark machined is a kind of special process method that does not have macroscopical operating force, and it has, and energy density is high, processing is not subjected to the characteristics such as material hardness restriction, is fit to very much the processing to hard crisp semi-conducting material.The semi-conductive feasibility of spark machined, processing mechanism and processing technology etc. have been had deep understanding through scientific research personnel's effort, the greatest problem that exists at present is exactly how to ensure that the semi-conducting material electrical spark working carries out stable automatic servo feeding man-hour.
When semi-conducting material adopts constant voltage source as seen from Figure 2 under three kinds of states of spark machined the electric current of (zero load, regular picture, short circuit), voltage characteristic and metal electric spark process and be essentially different.Because the existence of semiconductor bulk resistor, what voltage sampling signal was no longer only got is interpolar discharge voltage, but also comprises on the semiconductor bulk resistor and advance to electrically contact pressure drop on the end in contact potential barrier.Under regular picture and short-circuit condition, voltage can not significantly decrease when unloaded.This moment as the above-mentioned traditional method of servo-controlling of employing, system can all be used as all machining states Light Condition and process, this moment, the interpolar sampling voltage can be higher than reference voltage always, servo-drive system can improve constantly feed speed, until speed reaches the maximum that sets, in electrical spark working man-hour, this moment, electrode and semiconductor often were in short circuit and electrode by the semiconductor bending, even can break.So can't distinguish machining status man-hour with existing servo-drive system semiconductor is added, short-circuit conditions often appears in work in-process.At present, can only carry out constant speed feed according to technical staff's experience in the spark machined of semi-conducting material, so not only working (machining) efficiency is low, and machining accuracy also can't be guaranteed.
For heterogeneous material, such as carbon fibre material, although there is conductive materials, because resistivity of material is inhomogeneous, can not adopt equally existing servo sampling control method to process.
Summary of the invention
Thereby the objective of the invention is for feed speed adjustment in the existing spark machined is as occuring according to very easily causing excessive feeding or owing the feeding phenomenon take voltage detecting, affect the problem of process velocity and quality, invent a kind of take current impulse as according to regulating the electric spark method of servo-controlling based on the current impulse Probability Detection of electrode feed speed.
Technical scheme of the present invention is:
A kind of electric spark method of servo-controlling based on the current impulse Probability Detection is characterized in that take current signal as sampled signal, within the sampling period current impulse probability of occurrence is collected sample rate current pulse probability by sample circuit; Sample rate current pulse probability refers to that the number of the pulse of generation current accounts for the percentage of sampling period overall pulse number; Adopt microprocessor that sample rate current pulse probability is calculated and stores, sample rate current pulse probability and the current impulse probability that sets are compared, obtain scale factor as the SERVO CONTROL foundation, thus the feeding of control spark-erosion machine tool;
Scale factor=[the current impulse probability ÷ sample rate current pulse probability of setting]
n
N is one greater than 0 less than 1 number, and n is less, and the amplitude that each speed is regulated is just less, and velocity variations is more steady.If can cause reacting slow but the n value is too little, generally get 1/3≤n≤1/2.
According to the Wire-cut Electrical Discharge Machining experience as can be known, preferably in the situation, the regular picture impulse ratio is generally about 80% in discharged condition, and unloaded impulse ratio is about 10%, and the short circuit pulse ratio is about 10%.Because all can the generation current pulse in normal process pulse and short circuit pulse, so in discharged condition preferably in the situation, it is about 90% that current impulse produces probability.Because processing mode (Wire EDM, edm forming, electric-spark drilling etc.), object and condition are different, desirable current impulse probability also can change within the specific limits, is generally 70% ~ 95%.So the current impulse probability of setting is generally comparatively suitable between 70% ~ 95%.
When sample rate current pulse probability greater than the current impulse probability that sets, feed speed that then will this moment multiply by scale factor (this moment less than 1), to reduce feed speed; When the current impulse probability of sample rate current pulse probability less than setting, then feed speed at this moment be multiply by scale factor (this moment is greater than 1), improve feed speed; So that actual current pulse probability progressively trends towards the current impulse probability that sets; The pulse of described generation current comprises regular picture pulse and short circuit pulse.
The material of spark machined of the present invention comprise metal and electrical resistivity range between 0.01-100 Ω cm semi-conducting material and contain the heterogeneous body composite of conductive materials.
Electric discharge machining method of the present invention comprises Wire EDM, edm forming, electric-spark drilling processing and the combined machining method that relates to spark machined.
Described sample circuit is take current characteristics as servo foundation.
Described microprocessor is accepted the signal of sample circuit, thereby calculates the current impulse probability in the sampling period; Obtain scale factor according to the current impulse probability in the sampling period and the current impulse probability that sets, as servo foundation.
The described sampling period can change according to object and the processing request of processing.
The current impulse probability that sets is generally between 70% ~ 95%, can regulate according to object, processing request and the machined parameters etc. of processing.
Beneficial effect of the present invention:
Control accuracy of the present invention is high, especially is not subjected to the impact of machining state, and the energy Automatic-searching is to the desirable feed speed that sets.
The inventive method is simple and easy to do, only needs to increase a current impulse sample circuit and add simple software for calculation in original control circuit, can realize best constant speed control system.
The present invention is applied widely, is present unique method of servo-controlling as can be known for the semiconductor spark machined especially.
The present invention is conducive to improve process velocity and crudy, reduces the generation of the machining failures such as fracture of wire in Wire-cut Electrical Discharge Machining, can prolong time between failures, prolongs the service life of wire electrode.
Description of drawings
Fig. 1 is three kinds of discharge condition schematic diagrames of existing metal material spark machined.
Fig. 2 is three kinds of discharge condition schematic diagrames of existing semi-conducting material spark machined.
Fig. 3 is electric spark current-voltage waveform figure under the different feed speeds.
Fig. 4 is the schematic diagram that concerns that feed speed and current impulse produce probability.
The control flow chart of Fig. 5 method of servo-controlling of the present invention.
The structured flowchart schematic diagram of Fig. 6 current sampling system of the present invention.
Fig. 7 is the monocrystalline silicon exemplar schematic diagram that adopts traditional servo-drive system to cut.
Fig. 8 adopts the monocrystalline silicon exemplar schematic diagram that cuts based on the electric spark method of servo-controlling of current impulse Probability Detection of the present invention.
Fig. 9 adopts the monocrystalline silicon Varying-thickness cutting exemplar schematic diagram that cuts based on the electric spark method of servo-controlling of current impulse Probability Detection of the present invention.
Feed speed and cutting thickness relation curve during the cutting of Figure 10 single crystal silicon material wire electric discharge of the present invention Varying-thickness.
Table 1 is the single crystal silicon material Machining Technology with WEDM condition of the embodiment of the invention.
Table 1
| Project | Content |
| Workpiece material | P type single crystal silicon (2.1 Ω cm) |
| Cutting thickness (mm) | 10mm |
| Advance electric mode | Positive polarity processing |
| Electrode | Molybdenum filament (diameter 0.18mm) |
| Working media | Special-purpose working solution |
| Pulsewidth | 32μs |
| Dutycycle | 1:9 |
Table 2 is metal material Process Parameter of Wire Cut of Electric Discharge Machine Workings in the embodiment of the invention.
Table 2
| Project | Content |
| Workpiece material | 45 steel |
| Cutting thickness (mm) | 10mm |
| Advance electric mode | Positive polarity processing |
| Electrode | Molybdenum filament (diameter 0.18mm) |
| Working media | Special-purpose working solution |
| Pulsewidth | 20μs |
| Dutycycle | 1:6 |
The specific embodiment
The present invention is further illustrated below in conjunction with drawings and Examples.
Shown in Fig. 3-10.
Fig. 3 is electric spark current-voltage waveform figure under the different feed speeds under the employing table 1 technological parameter condition, by can clearly finding out among the figure, under different feed speeds, the probability that current impulse occurs has obvious difference, be that feed speed is faster, the current impulse occurrence probability is larger.Fig. 4 is that table 1 technological parameter condition lower feeding speed and current impulse produce the probabilistic relation curve.
The probability that occurs by current impulse is to distinguish the machining state of interpolar, and should strategy applicable equally for metal and semiconductor spark machined, therefore the spark machined Intelligent servo control method based on the current impulse Probability Detection of the present invention be the current impulse probability that measured take current sampling circuit as control according to carrying out the adjusting of speed.So-called current impulse probability refers to that the number of the pulse (comprising regular picture and short circuit pulse) of generation current accounts for the percentage of overall pulse number.Sampled signal is take pulsed current signal as the basis, adopts sample circuit (such as Fig. 6) within the sampling period current impulse to be taken a sample and obtains sampled signal; Microprocessor calculates the current impulse probability according to sampled signal and stores, and should the time period number of the number of times that occurs of sample rate current pulse and the theory pulse of this time period compare and carry out power less than between 1(1/2～1/3) power obtain scale factor, obtain the SERVO CONTROL foundation according to scale factor relatively, thus the feeding of control spark-erosion machine tool; It is a kind of method according to current impulse probability control feed speed.When sample rate current pulse probability greater than setting value, illustrate that the pulse number that electric current occurs in the sampling period surpasses desirable setting number this moment, the composition that present short circuit then is described increases, then will feed speed should be multiply by scale factor (this moment is less than 1) this moment, (ideal value such as setting is 90% to reduce feed speed, but actual value is 100%, illustrates that this moment machining state near dead short, reduction of speed); When sample rate current pulse probability less than set definite value, then will feed speed should be multiply by scale factor (this moment greater than 1) this moment, to improve feed speed.Guarantee that actual current pulse probability approaches the current impulse probability that sets.
Scale factor=[the current impulse probability ÷ sample rate current pulse probability of setting]
n
The material that the present invention was suitable for comprises metal, semi-conducting material (electrical resistivity range is between 0.01 ~ 100 Ω ㎝) and heterogeneous material.The electric discharge machining method that is suitable for comprises Wire EDM, edm forming and electric-spark drilling processing etc.The sampling period can change according to object and the processing request of processing during implementation.Setting the current impulse probability can change at any time according to object and the requirement of processing.
Example one.
Use traditional method of servo-controlling based on gap voltage, the working process parameter shown in the employing table 1 carries out the equal thickness Wire-cut Electrical Discharge Machining to monocrystalline silicon.The feed speed of initial setting is 80 μ m/s, because existing servo-drive system lost efficacy, system can't carry out the automatic adjusting of speed, can only carry out the feeding of constant speed (80 μ m/s).And because the existence of bulk resistor and contact resistance, existing system can't accurately identify short-circuit condition, when wire electrode by the workpiece bending, lathe is still with the speed feeding of 80 μ m/s, so that the serious skew of cutting track generation.The workpiece that finally cuts out as shown in Figure 7.
Use the electric spark method of servo-controlling based on the current impulse Probability Detection of the present invention instead, the working process parameter shown in the employing table 1 carries out the equal thickness Wire-cut Electrical Discharge Machining to monocrystalline silicon equally.The initial setting feed speed is 80 μ m/s, setting the current impulse probability is 85%, this moment, servo-control system can be regulated feed speed automatically according to the current impulse detection signal, reached best machining state, and the current impulse probability maintains about the value (85%) that sets.Under current machined parameters, feed speed can be adjusted to the optimal process speed of 48 μ m/s automatically, stablizes, efficient and accurate cutting, and cutting track overlaps with the program setting track, and the cutting exemplar as shown in Figure 8.
Example two.
Use traditional method of servo-controlling based on gap voltage, the working process parameter shown in the employing table 2 carries out Wire-cut Electrical Discharge Machining to 45 steel.The initial setting up maximal rate is 30 μ m/s, adding man-hour because this speed is lower than optimal process speed, so servo velocity maintains the high position of 28-29 μ m/s always.But because the restriction of maximal rate, present speed can only be adjusted in the scope of 0-30 μ m/s, can't reach optimal process speed.Need rule of thumb constantly to adjust maximal rate this moment and just can reach optimal process speed.
Use the electric spark method of servo-controlling based on the current impulse Probability Detection of the present invention instead, the working process parameter shown in the employing table 2 carries out Wire-cut Electrical Discharge Machining to 45 steel equally.It is 95% that the current impulse probability is set, and after the processing beginning, system regulates feed speed automatically, finally reaches the feed speed of 68 μ m/s, and the desirable process velocity corresponding with current set current impulse probability conforms to.
Example three.
Use the electric spark method of servo-controlling based on the current impulse Probability Detection of the present invention, the working process parameter shown in the employing table 1 carries out the Wire-cut Electrical Discharge Machining of Varying-thickness to monocrystalline silicon, and setting the current impulse probability is 70%.In process, along with the variation of thickness, system constantly adjusts feed speed, the optimum feed speed when reaching different thickness.Cut pictorial diagram as shown in Figure 9, the relation of feed speed and thickness as shown in figure 10 in the process.
Example four.
Technological parameter is processed shown in the employing table one, and setting ideal current pulse probability is 70%, and corresponding desirable process velocity is 40 μ m/s.If the n=1/2 in the scale factor formula.
If detecting current current impulse probability in a certain sense cycle is 50%, current feed speed is 30 μ m/s.
Scale factor=((70%) ÷ (50%))
1/2=1.18
Regulate current speed according to resulting scale factor.
V=30×1.18μm/s=35.4μm/s
If detecting current current impulse probability in a certain sense cycle is 95%, current feed speed is 55 μ m/s.
Scale factor=((70%) ÷ (95%))
1/2=0.86
Regulate current speed according to resulting scale factor.
V=55×0.94μm/s=47.3μm/s
By continuous adjusting so that the current impulse probability progressively trends towards the current impulse probability that sets.
Example five.
Technological parameter is processed shown in the employing table one, and setting ideal current pulse probability is 85%, and corresponding desirable process velocity is 48 μ m/s.If the n=1/3 in the scale factor formula.
If detecting current current impulse probability in a certain sense cycle is 45%, current feed speed is 28 μ m/s.
Scale factor=((85%) ÷ (45%))
1/3=1.24
Regulate current speed according to resulting scale factor.
V=28×1.24μm/s=34.72μm/s
If detecting current current impulse probability in a certain sense cycle is 98%, current feed speed is 60 μ m/s.
Scale factor=((85%) ÷ (98%))
1/3=0.95
Regulate current speed according to resulting scale factor.
V=60×0.95μm/s=57μm/s
By continuous adjusting so that the current impulse probability progressively trends towards the current impulse probability that sets.
Example six.
Technological parameter is processed shown in the employing table one, and setting ideal current pulse probability is 95%, and corresponding desirable process velocity is 55 μ m/s.If the n=5/12 in the scale factor formula.
If detecting current current impulse probability in a certain sense cycle is 45%, current feed speed is 28 μ m/s.
Scale factor=((95%) ÷ (45%))
5/12=1.37
Regulate current speed according to resulting scale factor.
V=28×1.37μm/s=38.36μm/s
If detecting current current impulse probability in a certain sense cycle is 99%, current feed speed is 69 μ m/s.
Scale factor=((95%) ÷ (99%))
5/12=0.98
Regulate current speed according to resulting scale factor.
V=69×0.98μm/s=67.62μm/s
By continuous adjusting so that the current impulse probability progressively trends towards the current impulse probability that sets.
The part that the present invention does not relate to all prior art that maybe can adopt same as the prior art is realized.
Claims (7)
1. the electric spark method of servo-controlling based on the current impulse Probability Detection is characterized in that take current signal as sampled signal, within the sampling period current impulse probability of occurrence is collected sample rate current pulse probability by sample circuit; Sample rate current pulse probability refers to that the number of the pulse of generation current accounts for the percentage of overall pulse number in the sampling period; Adopt microprocessor that sample rate current pulse probability is stored and calculated, sample rate current pulse probability and the current impulse probability that sets are compared, obtain scale factor as the SERVO CONTROL foundation, thus the feeding of control spark-erosion machine tool;
Scale factor can be tried to achieve according to following formula:
Scale factor=[the current impulse probability ÷ sample rate current pulse probability of setting]
n
In the formula: the value of exponential constant n is 1/3≤n≤1/2;
The current impulse probability of setting is according to different processing modes, situation and object desirable 70% ~ 95%;
When sample rate current pulse probability greater than the current impulse probability that sets, feed speed that then will this moment multiply by scale factor, reduces feed speed; When the current impulse probability of sample rate current pulse probability less than setting, then feed speed at this moment be multiply by scale factor, improve feed speed; So that actual current pulse probability progressively trends towards the current impulse probability that sets; The pulse of described generation current comprises regular picture pulse and short circuit pulse.
2. the method for servo-controlling shown in according to claim 1, it is characterized in that material that it is applicable to spark machined comprise metal, electrical resistivity range between 0.01-100 Ω cm semi-conducting material and contain the heterogeneous body composite of conductive materials.
3. the method for servo-controlling shown in according to claim 1, the electric discharge machining method that is suitable for comprises Wire EDM, edm forming, electric-spark drilling processing and the combined machining method that relates to spark machined.
4. the method for servo-controlling shown in according to claim 1 is characterized in that described sample circuit is take current characteristics as servo foundation.
5. the method for servo-controlling shown in according to claim 1 is characterized in that described microprocessor accepts the signal of sample circuit, thereby calculates the current impulse probability in the sampling period; Obtain scale factor according to the current impulse probability in the sampling period and the current impulse probability that sets, as servo foundation.
6. the method for servo-controlling shown in according to claim 1 is characterized in that the described sampling period can change according to processing mode, object and requirement.
7. the method for servo-controlling shown in according to claim 1 is characterized in that the current impulse probability that sets is relevant with efficient, surface quality, the export license of processing, and changes at any time for different processing requests.
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| CN106984877A (en) * | 2017-04-20 | 2017-07-28 | 南京航空航天大学 | The adjustable electric discharge ablation milling fast feed method of servo-controlling of cutting-in layering |
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| CN109158717A (en) * | 2018-10-24 | 2019-01-08 | 江苏德瑞加数控机床有限公司 | Spark discharge gap automatic control system based on self learning neural networks |
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| CN103909314A (en) * | 2014-03-27 | 2014-07-09 | 南京航空航天大学 | High-speed reciprocation wire cut electrical discharge machining working solution service life online fast determining method |
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| CN106984877A (en) * | 2017-04-20 | 2017-07-28 | 南京航空航天大学 | The adjustable electric discharge ablation milling fast feed method of servo-controlling of cutting-in layering |
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| CN107159983A (en) * | 2017-06-30 | 2017-09-15 | 自贡市嘉特数控机械制造有限公司 | Electric spark linear cutting machine feed processing unit (plant) and method |
| CN107159983B (en) * | 2017-06-30 | 2023-07-04 | 自贡市嘉特数控机械制造有限公司 | Cutting feed processing method of wire cut electric discharge machine |
| CN109158717A (en) * | 2018-10-24 | 2019-01-08 | 江苏德瑞加数控机床有限公司 | Spark discharge gap automatic control system based on self learning neural networks |
| CN109202192A (en) * | 2018-10-31 | 2019-01-15 | 清华大学 | Fine electric spark servo scanning machined parameters preferred method and system |
| CN109202192B (en) * | 2018-10-31 | 2019-09-17 | 清华大学 | Fine electric spark servo scanning machined parameters preferred method and system |
| CN109277657A (en) * | 2018-11-16 | 2019-01-29 | 苏州哈工乔德智能装备有限公司 | Adaptive discharge control system and method for wire wire cutting |
| CN111992827A (en) * | 2020-07-07 | 2020-11-27 | 宁波市江北数控设备厂 | Multi-line parallel electric spark cutting sampling control device |
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