CN103149466A - Electrolytic machining spark detection device - Google Patents
Electrolytic machining spark detection device Download PDFInfo
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- CN103149466A CN103149466A CN201210520763XA CN201210520763A CN103149466A CN 103149466 A CN103149466 A CN 103149466A CN 201210520763X A CN201210520763X A CN 201210520763XA CN 201210520763 A CN201210520763 A CN 201210520763A CN 103149466 A CN103149466 A CN 103149466A
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Abstract
The invention discloses an electrolytic machining spark detection device which comprises a signal integration circuit, an analog-to-digital conversion circuit, a fault diagnosis circuit and a fault output circuit. The signal integration circuit is used for achieving amplification of an input signal, the analog-to-digital conversion circuit is used for converting an analog signal into a digital signal, the fault diagnosis circuit extracts noise in signals by means of a digital filter through digital signal processing (DSP) software programming, the power density of the noise within unit time is obtained, whether spark faults occur is judged, and time when the spark faults occur is calculated according to a working clock. The fault output circuit converts detected results into passive buses output by a relay, and the fact that a direct current electrolytic power supply control loop protects a power supply and workpieces in time through fault signals is guaranteed.
Description
Technical field
The present invention relates to the spark pick-up unit that causes in a kind of spark pick-up unit, particularly a kind of electrolytic processing process.
Background technology
When electrochemical machining, owing to containing the reason such as impurity in electrolytic solution, often can cause the machining gap partial short-circuit, this short circuit is instantaneous often, when eliminating this instantaneous partial short-circuit, has spark and occurs.If spark is excessive or occurred frequently, need stop electrochemical machining work, in case cathode breakdown.
The spark pick-up unit is the device of measuring specially spark signal, and when spark exceeded electrochemical machining work threshold value, this device namely sent signal, cuts off the electricity supply.
The people such as Gao Song have designed the spark pick-up unit that is used for high-frequency impulse electrolysis power supply.This device is by the electric current of Hall element direct-detection MOSFET drain electrode, enters comparer and setting value in advance relatively through high speed photo coupling, as greater than setting value counter begin counting, 555 timers begin regularly simultaneously.Also no meter is not full to counter for timing, shows the spark that just accidentally occurs, and holding circuit is failure to actuate; As full at timer time inside counting device meter, show the continuity spark has occured the holding circuit action.
Yet prior art utilizes the amplitude of the pulse power current signal of Hall element collection to suddenly change to detect the spark fault, and due to the singularity of pulse power output voltage, this device can not gather voltage signal and carry out fault detect.
The invention discloses a kind of electrochemical machining spark pick-up unit, for the dc electrolysis power supply, this device can arbitrarily choose voltage or current signal detects, and has improved the dirigibility of using.
Summary of the invention
A kind of electrochemical machining spark pick-up unit, by signal integration circuit 1,1 ', analog to digital conversion circuit 2, fault judging circuit 3 and fault output circuit 4,4 ' consist of; Analog to digital conversion circuit 2 has two signal input part ADIN and ADIN', and the output terminal of being connected with 1' with signal integration circuit 1 respectively is connected; Analog to digital conversion circuit 2 output terminals are connected with fault judging circuit 3 input ends; Fault judging circuit 3 output terminals are connected respectively with fault output circuit 4,4 ' input end.
further, the signal integration circuit 1 of electrochemical machining spark pick-up unit comprises amplifier U16(OP27GS), resistance R 62, R63, R65, R66, R67, R68, voltage stabilizing diode D9, capacitor C 59, C60: input signal CURRENT_IN receives the in-phase input end of amplifier U16 by R67, the in-phase input end of U16 is connected with simulation ground AGND by R68, R62 is connected across between the output terminal of the reverse input end of U16 and U16, connecting resistance R63 between the reverse input end of U16 and simulation ground AGND, impedance is connected across between CURRENT_IN and AGND R65 as the circuit Input matching, the output signal of U16 is connected on the end of R66, the other end of R66 is the output signal ADIN of signal integration circuit, ADIN links the negative pole of voltage stabilizing diode D9, the D9 positive pole meets AGND, the pin 7 of U16 is received power supply+15V, cross-over connection filter capacitor C59 between pin 7 and AGND, the pin 4 of U16 is received power supply-15V, cross-over connection filter capacitor C60 between pin 4 and AGND.Signal integration circuit 1' is identical with signal integration circuit 1 circuit, comprises U16', resistance R 62', R63', R65', R66', R67', R68', voltage stabilizing diode D9'.
further, the analog to digital conversion circuit 2 of electrochemical machining spark pick-up unit has two signal input part ADIN and ADIN', comprises AD conversion chip U17 (AD7656), electrochemical capacitor C63, C64, C65, C66, C71, C72, polarity free capacitor C67, C68, C69, C70, C73, C74, the input signal ADIN of circuit and ADIN' receive respectively the pin 33 of U17, the pin 34 of 36, U17, 35, 40, 41, 46, 47, 50, 60 receive power supply+5VA, and pin 31 is received power supply+15V, cross-over connection filter capacitor C71 and C73 between 31 pin and AGND, and pin 30 is received power supply-15V, cross-over connection filter capacitor C72 and C74 between pin 30 and AGND, pin 53, 52, 49, 44, 43, 38, 37, 32 receive AGND, pin 24, 9 receive power vd DIO3V3, pin 29, 27, 61, 8, 25, receive digitally DGND, pin 26 is received power supply+5VD, and reference voltage input pin 51 is received power supply+2.5VA, cross-over connection filter capacitor C63 and C67 between 51 pin and AGND, pin 54, 56, 58 meet respectively benchmark decoupling capacitor C64C68, C65C69, C66C70, pin 17, 16, 15, 14, 13, 12, 11, 10, 7, 6, 5, 4, 3, 2, 1, 64 receive fault judging circuit, pin 21 as 16 position digital codings of circuit output, 22, 23, 19, 20, 63, 18, 28, 62 are connected with the acp chip of fault judging circuit as AD chip controls signal.
Further, the fault judging circuit 3 of electrochemical machining spark pick-up unit comprises U29 (TMS320F28335), output D0 ~ the D15 of analog to digital conversion circuit receives the pin 136,135,134,133,132,131,130,129,128,127,124,123,122,119,116,115 of U29, and the control signal of U17 is received the pin 111,148,75,110,137,149,150 of U29.
further, the fault output circuit 4 of electrochemical machining spark pick-up unit comprises optocoupler U8 (EL817), resistance R 19, R18, R20, R17, triode Q1 (MMBT2907A), relay K 1, LED 13, diode D4 (1N4148), the pin 1 of voltage dependent resistor (VDR) YM1:U8 is received power vd DIO3V3 by R19, the output signal DO1 of fault judging circuit receives the pin 2 of U8, signal is through the 4 pin outputs of light-coupled isolation by U8, receive the end of R18, the R18 other end is received the B pin of Q1, R17 is connected across between the B pin and E pin of Q1, the E pin of Q1 is received power vd O5V, the coil of K1, D4, LED13 three-line and being connected between the C pin and VDO0V of Q1 on the R20 string, the output of relay is often opened node as the output signal of circuit, voltage dependent resistor (VDR) YM1 is connected in parallel on and exports two ends.Fault output circuit 4 ' is identical with fault output circuit 4 circuits, comprise optocoupler U9 (EL817), resistance R 19', R18', R20', R17', triode Q1'(MMBT2907A), relay K 1', LED 13', diode D4'(1N4148), voltage dependent resistor (VDR) YM1 '.
further, the signal integration circuit 1 of electrochemical machining spark pick-up unit, 1 ' is the ratio amplifying circuit, the ratio amplifying circuit comprises amplifier U16 (OP27GS), R62, R63, R66, R67, voltage stabilizing diode D9, input signal CURRENT_IN receives the in-phase input end of U16 by R67, R62 is connected across between the output terminal of the reverse input end of U16 and U16, connecting resistance R63 between the reverse input end of U16 and simulation ground AGND, the output signal of U16 is connected on the end of R66, the other end of R66 is the output signal ADIN of signal integration circuit, ADIN links the negative pole of voltage stabilizing diode D9, the D9 positive pole meets AGND, the pin 7 of U16 is received power supply+15V, the pin 4 of U16 is received power supply-15V.
Further, the analog to digital conversion circuit of electrochemical machining spark pick-up unit 2 adopts the digital filter of inductance capacitance modes to extract noise Hiout in signal, i.e. sign mutation, and its differential equation is y (n)=f
s/ f
c* (x (n)-x (n-1)), y in formula (n) is wave filter output, and x (n) is current input, and x (n-1) is last input value, f
cBe cutoff frequency, f
sBe sample frequency.
Further, the analog to digital conversion circuit 2 of electrochemical machining spark pick-up unit is resistance capacitance formula digital filter, y (n)=x (n)-f
c/ f
s* ∑ y (n-1), wherein, y (n) is wave filter output, x (n) is current input, f
cBe cutoff frequency, f
sBe sample frequency, ∑ y (n-1) is 0 to n-1 item output valve sum.
Further, the fault judging circuit 3 of electrochemical machining spark pick-up unit is realized the fault judgement by the 32 bit CPU timer TIMER0 of TMS320F283335DSP:
The Val if input signal is averaged, self-adaptation parameter K=x% * Val (x% span 5%-10%), extract signal noise Hiout with the inductance and capacitance type digital filter simultaneously, compare Hiout and Val, calculate result relatively with counter, obtain Carrier To Noise Power Density in the unit interval, judge whether to break down.
Further, the fault judging circuit 3 acp chip TMS320F28335 of electrochemical machining spark pick-up unit can realize with other floating types or fixed point type DSP; Acp chip DSP can use chip microcontroller.
Description of drawings
Fig. 1 is electrochemical machining spark structure of the detecting device schematic diagram;
Fig. 2 is signal integration circuit 1,1 ' circuit diagram;
Fig. 3 is analog to digital conversion circuit 2 circuit diagrams; Comprise Fig. 3 A and Fig. 3 B that cut along dotted line;
Fig. 4 is fault judging circuit 3 circuit diagrams, comprises Fig. 4-1 and Fig. 4-2; Wherein, Fig. 4-1 comprises Fig. 4-1A and the 4-1B that cuts along dotted line;
Fig. 5 is fault output circuit 4,4 ' circuit diagram;
Fig. 6 is the judgement schematic flow sheet of fault judging circuit 3;
Fig. 7 is that signal integration circuit 1,1 ' is the circuit diagram of ratio amplifying circuit.
Embodiment
In order to fully understand content of the present invention, below in conjunction with specific embodiment, technical scheme of the present invention is done further introduction and explanation, but be not limited to this.
This spark pick-up unit is made of two signal integration circuit, an analog to digital conversion circuit, a fault judging circuit, two fault output circuits.D/A converting circuit has two signal input part ADIN and ADIN', output terminal with signal integration circuit 1 and 1' is connected respectively, analog to digital conversion circuit output 16 bit digital quantity coded signal D0 ~ D16, input signal as fault judging circuit, change the variation of corresponding digitally encoded signal by judgement and voltage and current, judge whether the length of flashing fault-signal and the signal time that breaks down.Occur as the no-spark fault, DO1, DO2 are low level, have fault occur but be no more than setting-up time DO1 high level DO2 low level, have fault to occur and surpass setting-up time DO1 high level DO2 high level.
analog to digital conversion circuit has two signal input part ADIN and ADIN', comprises AD conversion chip U17 (AD7656), electrochemical capacitor C63, C64, C65, C66, C71, C72, polarity free capacitor C67, C68, C69, C70, C73, C74, the input signal ADIN of circuit and ADIN' receive respectively the pin 33 of U17, the pin 34 of 36, U17, 35, 40, 41, 46, 47, 50, 60 receive power supply+5VA, and pin 31 is received power supply+15V, cross-over connection filter capacitor C71 and C73 between 31 pin and AGND, and pin 30 is received power supply-15V, cross-over connection filter capacitor C72 and C74 between pin 30 and AGND, pin 53, 52, 49, 44, 43, 38, 37, 32 receive AGND, pin 24, 9 receive power vd DIO3V3, pin 29, 27, 61, 8, 25, receive digitally DGND, pin 26 is received power supply+5VD, and reference voltage input pin 51 is received power supply+2.5VA, cross-over connection filter capacitor C63 and C67 between 51 pin and AGND, pin 54, 56, 58 meet respectively benchmark decoupling capacitor C64C68, C65C69, C66C70, pin 17, 16, 15, 14, 13, 12, 11, 10, 7, 6, 5, 4, 3, 2, 1, 64 receive fault judging circuit, pin 21 as 16 position digital codings of circuit output, 22, 23, 19, 20, 63, 18, 28, 62 are connected with the acp chip of fault judging circuit as AD chip controls signal.
Fault judging circuit comprises U29 (TMS320F28335), output D0 ~ the D15 of analog to digital conversion circuit receives the pin 136,135,134,133,132,131,130,129,128,127,124,123,122,119,116,115 of U29, and the control signal of U17 is received the pin 111,148,75,110,137,149,150 of U29.U29 judges whether to produce the time that the spark fault namely produces fault by the signal that receives, thereby output fault judgement signal DO1, DO2 are to the fault output circuit.The judgement of fault is by the 32 bit CPU timer TIMER0 implement of interruption functions of TMS320F283335DSP, the function that realizes in interrupt response comprises: to the input signal Val that averages, be used for calculating self-adaptation parameter K, extract signal noise Hiout with the inductance and capacitance type digital filter simultaneously, compare Hiout and Val, calculate result relatively with counter, obtain Carrier To Noise Power Density in the unit interval, judge whether to break down.
Claims (10)
1. an electrochemical machining spark pick-up unit, is characterized in that, by signal integration circuit 1,1 ', analog to digital conversion circuit 2, fault judging circuit 3 and fault output circuit 4,4 ' consist of; Analog to digital conversion circuit 2 has two signal input part ADIN and ADIN', and the output terminal of being connected with 1' with signal integration circuit 1 respectively is connected; Analog to digital conversion circuit 2 output terminals are connected with fault judging circuit 3 input ends; Fault judging circuit 3 output terminals are connected respectively with fault output circuit 4,4 ' input end.
2. a kind of electrochemical machining spark pick-up unit as claimed in claim 1, it is characterized in that, the signal integration circuit 1 of electrochemical machining spark pick-up unit comprises amplifier U16(OP27GS), resistance R 62, R63, R65, R66, R67, R68, voltage stabilizing diode D9, capacitor C 59, C60: input signal CURRENT_IN receives the in-phase input end of amplifier U16 by R67, the in-phase input end of U16 is connected with simulation ground AGND by R68, R62 is connected across between the output terminal of the reverse input end of U16 and U16, connecting resistance R63 between the reverse input end of U16 and simulation ground AGND, impedance is connected across between CURRENT_IN and AGND R65 as the circuit Input matching, the output signal of U16 is connected on the end of R66, the other end of R66 is the output signal ADIN of signal integration circuit, ADIN links the negative pole of voltage stabilizing diode D9, the D9 positive pole meets AGND, the pin 7 of U16 is received power supply+15V, cross-over connection filter capacitor C59 between pin 7 and AGND, the pin 4 of U16 is received power supply-15V, cross-over connection filter capacitor C60 between pin 4 and AGND.Signal integration circuit 1 ' identical with signal integration circuit 1 circuit comprises U16', resistance R 62', R63', R65', R66', R67', R68', voltage stabilizing diode D9'.
3. a kind of electrochemical machining spark pick-up unit as claimed in claim 1, is characterized in that, the analog to digital conversion circuit 2 of electrochemical machining spark pick-up unit has two signal input part ADIN and ADIN', comprises AD conversion chip U17 (AD7656), electrochemical capacitor C63, C64, C65, C66, C71, C72, polarity free capacitor C67, C68, C69, C70, C73, C74, the input signal ADIN of circuit and ADIN' receive respectively the pin 33 of U17, the pin 34 of 36, U17, 35, 40, 41, 46, 47, 50, 60 receive power supply+5VA, and pin 31 is received power supply+15V, cross-over connection filter capacitor C71 and C73 between 31 pin and AGND, and pin 30 is received power supply-15V, cross-over connection filter capacitor C72 and C74 between pin 30 and AGND, pin 53, 52, 49, 44, 43, 38, 37, 32 receive AGND, pin 24, 9 receive power vd DIO3V3, pin 29, 27, 61, 8, 25, receive digitally DGND, pin 26 is received power supply+5VD, and reference voltage input pin 51 is received power supply+2.5VA, cross-over connection filter capacitor C63 and C67 between 51 pin and AGND, pin 54, 56, 58 meet respectively benchmark decoupling capacitor C64C68, C65C69, C66C70, pin 17, 16, 15, 14, 13, 12, 11, 10, 7, 6, 5, 4, 3, 2, 1, 64 receive fault judging circuit, pin 21 as 16 position digital codings of circuit output, 22, 23, 19, 20, 63, 18, 28, 62 are connected with the acp chip of fault judging circuit as AD chip controls signal.
4. a kind of electrochemical machining spark pick-up unit as claimed in claim 1, it is characterized in that, the fault judging circuit 3 of electrochemical machining spark pick-up unit comprises U29 (TMS320F28335), output D0 ~ the D15 of analog to digital conversion circuit receives the pin 136,135,134,133,132,131,130,129,128,127,124,123,122,119,116,115 of U29, and the control signal of U17 is received the pin 111,148,75,110,137,149,150 of U29.
5. a kind of electrochemical machining spark pick-up unit as claimed in claim 1, it is characterized in that, the fault output circuit 4 of electrochemical machining spark pick-up unit comprises optocoupler U8 (EL817), resistance R 19, R18, R20, R17, triode Q1 (MMBT2907A), relay K 1, LED 13, diode D4 (1N4148), the pin 1 of voltage dependent resistor (VDR) YM1:U8 is received power vd DIO3V3 by R19, the output signal DO1 of fault judging circuit receives the pin 2 of U8, signal is through the 4 pin outputs of light-coupled isolation by U8, receive the end of R18, the R18 other end is received the B pin of Q1, R17 is connected across between the B pin and E pin of Q1, the E pin of Q1 is received power vd O5V, the coil of K1, D4, LED13 three-line and being connected between the C pin and VDO0V of Q1 on the R20 string, the output of relay is often opened node as the output signal of circuit, voltage dependent resistor (VDR) YM1 is connected in parallel on and exports two ends.Fault output circuit 4 ' is identical with fault output circuit 4 circuits, comprises optocoupler U9 (EL817), resistance R 19', R18', R20', R17', triode Q1'(MMBT2907A), relay K 1', LED 13', diode D4'(1N4148), voltage dependent resistor (VDR) YM1'.
6. a kind of electrochemical machining spark pick-up unit as claimed in claim 2, it is characterized in that, the signal integration circuit 1 of electrochemical machining spark pick-up unit, 1 ' is the ratio amplifying circuit, the ratio amplifying circuit comprises amplifier U16 (OP27GS), R62, R63, R66, R67, voltage stabilizing diode D9, input signal CURRENT_IN receives the in-phase input end of U16 by R67, R62 is connected across between the output terminal of the reverse input end of U16 and U16, connecting resistance R63 between the reverse input end of U16 and simulation ground AGND, the output signal of U16 is connected on the end of R66, the other end of R66 is the output signal ADIN of signal integration circuit, ADIN links the negative pole of voltage stabilizing diode D9, the D9 positive pole meets AGND, the pin 7 of U16 is received power supply+15V, the pin 4 of U16 is received power supply-15V.
7. a kind of electrochemical machining spark pick-up unit as claimed in claim 3, it is characterized in that, the analog to digital conversion circuit 2 of electrochemical machining spark pick-up unit adopts the digital filter of inductance capacitance modes to extract noise Hiout in signal, i.e. sign mutation, and its differential equation is y (n)=f
s/ f
c* (x (n)-x (n-1)), y in formula (n) is wave filter output, and x (n) is current input, and x (n-1) is last input value, f
cBe cutoff frequency, f
sBe sample frequency.
8. a kind of electrochemical machining spark pick-up unit as claimed in claim 3, is characterized in that, the analog to digital conversion circuit 2 of electrochemical machining spark pick-up unit is resistance capacitance formula digital filter, y (n)=x (n)-f
c/ f
s* ∑ y (n-1), wherein, y (n) is wave filter output, x (n) is current input, f
cBe cutoff frequency, f
sBe sample frequency, ∑ y (n-1) is 0 to n-1 item output valve sum.
9. a kind of electrochemical machining spark pick-up unit as claimed in claim 4, is characterized in that, the fault judging circuit 3 of electrochemical machining spark pick-up unit is realized the fault judgement by the 32 bit CPU timer TIMER0 of TMS320F283335DSP:
The Val if input signal is averaged, self-adaptation parameter K=x% * Val (x% span 5%-10%), extract signal noise Hiout with the inductance and capacitance type digital filter simultaneously, compare Hiout and Val, calculate result relatively with counter, obtain Carrier To Noise Power Density in the unit interval, judge whether to break down.
10. a kind of electrochemical machining spark pick-up unit as claimed in claim 4, is characterized in that, the fault judging circuit 3 acp chip TMS320F28335 of electrochemical machining spark pick-up unit can realize with other floating types or fixed point type DSP; Acp chip DSP can use chip microcontroller.
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| CN201210520763.XA CN103149466B (en) | 2012-12-06 | 2012-12-06 | Electrochemical machining spark detection device |
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| CN201210520763.XA CN103149466B (en) | 2012-12-06 | 2012-12-06 | Electrochemical machining spark detection device |
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| CN103149466B CN103149466B (en) | 2015-12-09 |
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