CN102909447B - 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 PDF

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CN102909447B
CN102909447B CN201210441231.7A CN201210441231A CN102909447B CN 102909447 B CN102909447 B CN 102909447B CN 201210441231 A CN201210441231 A CN 201210441231A CN 102909447 B CN102909447 B CN 102909447B
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probability
current pulse
current
pulse
servo
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CN102909447A (en
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刘志东
邱明波
潘慧君
田宗军
沈理达
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Nanjing University of Aeronautics and Astronautics
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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

Electric spark method of servo-controlling based on current impulse Probability Detection
Technical field
The present invention relates to a kind of spark erosion technique, especially a control method for Electrode in EDM feed speed, specifically a kind of electric spark method of servo-controlling based on current impulse Probability Detection of the heterogeneous body composite spark machined that is applicable to metal, semi-conducting material and contain conductive materials.
Background technology
Spark machined is a kind of special process method of the high temperature galvanic action ablation material that produces while utilizing two interpolar pulsed discharges.It mainly contains following characteristics:
1. can process material and complex-shaped workpieces that conventional machining processes method is difficult to cutting;
2. add man-hour without macroscopical cutting force;
3. do not produce the defect such as burr and tool marks rill;
4. tool-electrode material is without harder than workpiece material.
For maintaining 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 is mainly the size that indirectly reflects gap by workpiece and interelectrode average voltage size, and main method has average voltage detection method and crest voltage detection method.
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.From the current-voltage characteristic of three kinds of discharge conditions of Fig. 1 metal material spark machined, under zero load, regular picture and short-circuit condition, its voltage characteristic has obvious difference.Adding man-hour, if floating voltage pulse is more, its interpolar average voltage can increase; If short-circuit voltage pulse is more, interpolar average voltage will reduce.When interpolar average voltage is higher than reference voltage, illustrate that now discharging gap is greater than desirable discharging gap, in owing tracking mode, should increase feed speed; When average voltage is lower than reference voltage, illustrate that now discharging gap is less than desirable discharging gap, in crossing tracking mode, should reduce feed speed; When average voltage is close with reference voltage, illustrate that now discharging gap is more satisfactory discharging gap, maintain current electrode feed speed.Work in-process can reach desirable feed speed by adjusting servo feed.
But existing method of servo-controlling exists limitation, need man-hour the various parameters of manual adjustment to reach desirable feed speed adding.Reponse system can only be carried out servo adjusting in the scope setting, and cannot reach automatically best feed speed, so depend on to a great extent operating personnel's experience.
Along with scientific and technological development, semi-conducting material is applied 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 features such as elastic limit of materials and intensity approach very much, traditional machining process is very difficult in the time running into high thickness, non-rectilinear machined surface.Spark machined is a kind of special process method that there is no macroscopical operating force, and it has, and energy density is high, processing is not subject to the features such as material hardness restriction, is applicable 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 to deep understanding through scientific research personnel's effort, the greatest problem existing is at present exactly how to ensure that 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 the processing of metal electric spark are essentially different.Due to the existence of semiconductor bulk resistor, what voltage sampling signal was no longer only got is interpolar discharge voltage, but also comprises on semiconductor bulk resistor and enter to electrically contact the pressure drop in end in contact potential barrier.Under regular picture and short-circuit condition, when voltage is more unloaded, can not significantly decrease.Now as adopted above-mentioned traditional method of servo-controlling, system can be all used as Light Condition processing by all machining states, now interpolar sampling voltage can be always higher than reference voltage, servo-drive system can improve constantly feed speed, until speed reaches the maximum setting, in electrical spark working man-hour, now electrode and semiconductor often in short circuit and electrode by semiconductor bending, even can break.So cannot distinguish machining status man-hour by existing servo-drive system semiconductor is added, often there is short-circuit conditions in work in-process.At present, in the spark machined of semi-conducting material, can only carry out constant speed feed according to technical staff's experience, so not only working (machining) efficiency is low, and machining accuracy also cannot be guaranteed.
For heterogeneous material, 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 object of the invention is for feed speed adjustment in existing spark machined is take voltage detecting as occurring according to very easily causing excessive feeding or owing feeding phenomenon, affect the problem of process velocity and quality, invent a kind of take current impulse as the electric spark method of servo-controlling based on current impulse Probability Detection according to regulating electrode feed speed.
Technical scheme of the present invention is:
An electric spark method of servo-controlling based on 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 to 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 stored, sample rate current pulse probability and the current impulse probability setting are compared, obtain scale factor as SERVO CONTROL foundation, thereby control spark-erosion machine tool feeding;
Scale factor=[the current impulse probability ÷ sample rate current pulse probability of setting] n
N one is greater than 0 number that is less than 1, and n is less, and the amplitude that each speed regulates is just less, and velocity variations is more steady.If but n value is too little, can cause reacting slow, generally get 1/3≤n≤1/2.
Known according to Wire-cut Electrical Discharge Machining experience, in the good situation of discharged condition, regular picture impulse ratio is generally 80% left and right, and unloaded impulse ratio is 10% left and right, and short circuit pulse ratio is 10% left and right.Because all can generation current pulse in normal process pulse and short circuit pulse, so in the good situation of discharged condition, it is 90% left and right that current impulse produces probability.Due to processing mode (Wire EDM, edm forming, electric-spark drilling etc.), object and condition difference, 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 is greater than the current impulse probability setting, feed speed is now multiplied by scale factor (being now less than 1), to reduce feed speed; When sample rate current pulse probability is less than the current impulse probability of setting, feed speed is now multiplied by scale factor (being now greater than 1), improve feed speed; Make actual current pulse probability progressively trend towards the current impulse probability setting; The pulse of described generation current comprises regular picture pulse and short circuit pulse.
The material of spark machined of the present invention comprises metal and the semi-conducting material of electrical resistivity range between 0.01-100 Ω cm and the heterogeneous body composite that contains conductive materials.
Electric discharge machining method of the present invention comprises Wire EDM, edm forming, electric-spark drilling processing and relates to the combined machining method of 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 setting, as servo foundation.
The described sampling period can change according to object and the processing request of processing.
The current impulse probability setting 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, is not especially subject to the impact of machining state, and energy Automatic-searching is to the desirable feed speed setting.
The inventive method is simple and easy to do, and only need in original control circuit, increase a current impulse sample circuit adds simple software for calculation, can realize best constant speed control system.
The present invention is applied widely, is especially current known unique method of servo-controlling for semiconductor spark machined.
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 extend time between failures, extends the service life of wire electrode.
Accompanying drawing explanation
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 different feed speeds.
Fig. 4 is the schematic diagram that is related to 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 is the monocrystalline silicon exemplar schematic diagram that adopts the electric spark method of servo-controlling based on current impulse Probability Detection of the present invention to cut.
Fig. 9 is the monocrystalline silicon Varying-thickness cutting exemplar schematic diagram that adopts the electric spark method of servo-controlling based on current impulse Probability Detection of the present invention to cut.
Feed speed and cutting thickness relation curve when 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 present invention.
Table 1
Project Content
Workpiece material P type single crystal silicon (2.1 Ω cm)
Cutting thickness (mm) 10mm
Enter electric mode Positive polarity processing
Electrode Molybdenum filament (diameter 0.18mm)
Working media Special 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 present invention.
Table 2
Project Content
Workpiece material 45 steel
Cutting thickness (mm) 10mm
Enter electric mode Positive polarity processing
Electrode Molybdenum filament (diameter 0.18mm)
Working media Special working solution
Pulsewidth 20μs
Dutycycle 1:6
The specific embodiment
Below in conjunction with drawings and Examples, the present invention is further illustrated.
As shown in Fig. 3-10.
Fig. 3 is electric spark current-voltage waveform figure under different feed speeds under employing table 1 technological parameter condition, by can clearly finding out in figure, under different feed speeds, the probability that current impulse occurs has obvious difference, be that feed speed is faster, current impulse occurrence probability is larger.Fig. 4 is that table 1 technological parameter condition lower feeding speed and current impulse produce probabilistic relation curve.
The probability occurring by current impulse is to distinguish the machining state of interpolar, and this strategy is applicable equally for metal and semiconductor spark machined, therefore the spark machined Intelligent servo control method based on current impulse Probability Detection of the present invention is that the current impulse probability being measured take current sampling circuit carries out the adjusting of speed as controlling foundation.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, take pulsed current signal as basis, adopts sample circuit (as Fig. 6) within the sampling period, current impulse to be sampled and obtains sampled signal; Microprocessor calculates current impulse probability and stores according to sampled signal, and the number of times that this sample rate current pulse is occurred time period compare and carry out power with the number of this time period theory pulse be less than between 1(1/2~1/3) power obtain scale factor, obtain SERVO CONTROL foundation according to scale factor relatively, thereby control spark-erosion machine tool feeding; A kind of according to the method for current impulse probability control feed speed.When sample rate current pulse probability is greater than setting value, now illustrate that the pulse number that in the sampling period, electric current occurs exceedes desirable setting number, the composition that current short circuit is described increases, will now feed speed should be multiplied by scale factor (being now less than 1), to reduce feed speed (if the ideal value of setting is 90%, but actual value is 100%, illustrate that now machining state has approached dead short, reduction of speed); When sample rate current pulse probability is less than set definite value, will now feed speed should be multiplied by scale factor (being now greater than 1), to improve feed speed.Guarantee that actual current pulse probability approaches the current impulse probability setting.
Scale factor=[the current impulse probability ÷ sample rate current pulse probability of setting] n
The applicable material of the present invention comprises metal, semi-conducting material (electrical resistivity range is between 0.01 ~ 100 Ω ㎝) and heterogeneous material.Applicable electric discharge machining method comprises Wire EDM, edm forming and electric-spark drilling processing etc.When concrete enforcement, the sampling period can change according to object and the processing request of processing.Setting current impulse probability can and require according to the object of processing to change at any time.
example one.
Use traditional method of servo-controlling based on gap voltage, the working process parameter shown in employing table 1 carries out equal thickness Wire-cut Electrical Discharge Machining to monocrystalline silicon.The feed speed of initial setting is 80 μ m/s, and because existing servo-drive system lost efficacy, system cannot be carried out the automatic adjusting of speed, can only carry out the feeding of constant speed (80 μ m/s).And due to the existence of bulk resistor and contact resistance, existing system cannot accurately be identified short-circuit condition, when wire electrode is by workpiece bending, lathe, still with the speed feeding of 80 μ m/s, makes cutting track that serious skew occur.The workpiece finally cutting out as shown in Figure 7.
Use the electric spark method of servo-controlling based on current impulse Probability Detection of the present invention instead, the working process parameter shown in employing table 1 carries out equal thickness Wire-cut Electrical Discharge Machining to monocrystalline silicon equally.Initial setting feed speed is 80 μ m/s, setting current impulse probability is 85%, now servo-control system can regulate feed speed automatically according to current impulse detection signal, reaches best machining state, and current impulse probability maintains value (85%) left and right setting.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 program setting track, and 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 employing table 2 carries out Wire-cut Electrical Discharge Machining to 45 steel.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 a high position of 28-29 μ m/s always.But due to the restriction of maximal rate, present speed can only be adjusted in the scope of 0-30 μ m/s, cannot reach optimal process speed.Now need rule of thumb constantly to adjust maximal rate and just can reach optimal process speed.
Use the electric spark method of servo-controlling based on current impulse Probability Detection of the present invention instead, the working process parameter shown in employing table 2 carries out Wire-cut Electrical Discharge Machining to 45 steel equally.It is 95% that current impulse probability is set, and after processing starts, 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 current impulse Probability Detection of the present invention, the working process parameter shown in employing table 1 carries out the Wire-cut Electrical Discharge Machining of Varying-thickness to monocrystalline silicon, and setting current impulse probability is 70%.In process, along with the variation of thickness, system is constantly adjusted feed speed, the optimum feed speed while reaching different thickness.As shown in Figure 9, in process, the relation of feed speed and thickness as shown in figure 10 for cutting pictorial diagram.
example four.
Shown in employing table one, technological parameter is processed, and setting ideal current pulse probability is 70%, and corresponding desirable process velocity is 40 μ m/s.If the n=1/2 in scale factor formula.
If detect in a certain sense cycle, current current impulse probability is 50%, and current feed speed is 30 μ m/s.
Scale factor=((70%) ÷ (50%)) 1/2=1.18
Regulate current speed according to obtained scale factor.
V=30×1.18μm/s=35.4μm/s
If detect in a certain sense cycle, current current impulse probability is 95%, and current feed speed is 55 μ m/s.
Scale factor=((70%) ÷ (95%)) 1/2=0.86
Regulate current speed according to obtained scale factor.
V=55×0.94μm/s=47.3μm/s
Make current impulse probability progressively trend towards the current impulse probability setting by continuous adjusting.
example five.
Shown in employing table one, technological parameter is processed, and setting ideal current pulse probability is 85%, and corresponding desirable process velocity is 48 μ m/s.If the n=1/3 in scale factor formula.
If detect in a certain sense cycle, current current impulse probability is 45%, and current feed speed is 28 μ m/s.
Scale factor=((85%) ÷ (45%)) 1/3=1.24
Regulate current speed according to obtained scale factor.
V=28×1.24μm/s=34.72μm/s
If detect in a certain sense cycle, current current impulse probability is 98%, and current feed speed is 60 μ m/s.
Scale factor=((85%) ÷ (98%)) 1/3=0.95
Regulate current speed according to obtained scale factor.
V=60×0.95μm/s=57μm/s
Make current impulse probability progressively trend towards the current impulse probability setting by continuous adjusting.
example six.
Shown in employing table one, technological parameter is processed, and setting ideal current pulse probability is 95%, and corresponding desirable process velocity is 55 μ m/s.If the n=5/12 in scale factor formula.
If detect in a certain sense cycle, current current impulse probability is 45%, and current feed speed is 28 μ m/s.
Scale factor=((95%) ÷ (45%)) 5/12=1.37
Regulate current speed according to obtained scale factor.
V=28×1.37μm/s=38.36μm/s
If detect in a certain sense cycle, current current impulse probability is 99%, and current feed speed is 69 μ m/s.
Scale factor=((95%) ÷ (99%)) 5/12=0.98
Regulate current speed according to obtained scale factor.
V=69×0.98μm/s=67.62μm/s
Make current impulse probability progressively trend towards the current impulse probability setting by continuous adjusting.
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 (5)

1. the electric spark method of servo-controlling based on 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 to 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 setting are compared, obtain scale factor as SERVO CONTROL foundation, thereby control spark-erosion machine tool feeding;
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 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 is greater than the current impulse probability setting, feed speed is now multiplied by scale factor, reduce feed speed; When sample rate current pulse probability is less than the current impulse probability of setting, feed speed is now multiplied by scale factor, improve feed speed; Make actual current pulse probability progressively trend towards the current impulse probability setting; The pulse of described generation current comprises regular picture pulse and short circuit pulse.
2. according to the method for servo-controlling shown in claim 1, it is characterized in that the material that it is applicable to spark machined comprises metal, the semi-conducting material of electrical resistivity range between 0.01-100 Ω cm and the heterogeneous body composite that contains conductive materials.
3. according to the method for servo-controlling shown in claim 1, applicable electric discharge machining method comprises Wire EDM, edm forming, electric-spark drilling processing and relates to the combined machining method of spark machined.
4. according to the method for servo-controlling shown in claim 1, it is characterized in that the described sampling period can change according to processing mode, object and requirement.
5. according to the method for servo-controlling shown in claim 1, it is characterized in that the current impulse probability setting is relevant with efficiency, surface quality, the export license of processing, and change at any time for different processing requests.
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