CN108247162B - Numerical control small Kong Jidian pole rotation control device and method - Google Patents

Numerical control small Kong Jidian pole rotation control device and method Download PDF

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CN108247162B
CN108247162B CN201810225304.6A CN201810225304A CN108247162B CN 108247162 B CN108247162 B CN 108247162B CN 201810225304 A CN201810225304 A CN 201810225304A CN 108247162 B CN108247162 B CN 108247162B
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rotor
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CN108247162A (en
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李学哲
姚子巍
李长宁
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Suzhou University of Science and Technology
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/14Making holes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H1/00Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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Abstract

本申请公开了一种数控小孔机电极旋转控制装置以及该装置的应用方法和配置这种装置的数控小孔机,其中电极旋转控制装置包括步进电机,步进电机通过旋转头驱动电极管,还包括:带有中心孔的转子,所述转子上制有编码图形;设于所述中心孔中的橡胶环,所述电极管穿入所述橡胶环中;与所述转子相配合的定子;与所述定子相对固定、且与所述编码图形相配合以用于检测所述转子转速的线阵扫描摄像机;为所述定子供电进而带动所述转子旋转、且与所述步进电机的电机驱动器以及所述线阵扫描摄像机均相连的驱动电路。本申请可有效提高小孔加工质量。

Figure 201810225304

This application discloses a numerically controlled small hole machine electrode rotation control device, an application method of the device and a numerically controlled small hole machine equipped with such a device, wherein the electrode rotation control device includes a stepping motor, and the stepping motor drives the electrode tube through the rotating head , also includes: a rotor with a central hole, on which a code pattern is formed; a rubber ring arranged in the central hole, and the electrode tube penetrates into the rubber ring; Stator; a line scan camera that is relatively fixed to the stator and cooperates with the coding pattern to detect the rotation speed of the rotor; supplies power to the stator to drive the rotor to rotate, and is connected to the stepper The motor driver of the motor and the drive circuit connected to the line scan camera. The application can effectively improve the processing quality of small holes.

Figure 201810225304

Description

数控小孔机电极旋转控制装置及方法Electrode rotation control device and method for numerically controlled small hole machine

技术领域technical field

本申请涉及数控小孔机领域,具体涉及一种数控小孔机电极旋转控制装置以及该装置的应用方法和配置这种装置的数控小孔机。The present application relates to the field of numerically controlled small hole machines, in particular to a numerically controlled small hole machine electrode rotation control device, an application method of the device, and a numerically controlled small hole machine equipped with such a device.

背景技术Background technique

数控电加工小孔机(以下简称小孔机)属于电火花加工机床的一种,是利用连续移动的细长中空铜管作为工具电极(以下简称电极),通过从铜管孔穿过的介质(工作液)与工件发生放电,对工件进行脉冲火花放电蚀除金属达到穿孔的目的,该设备主要用于加工超硬钢材、硬质合金等可导电性物质的微细孔。电火花蚀除加工又是数控小孔机的核心部分,其主要功能是:1、根据间隙电压来调节电极加工进给速度以控制放电间隙大小;2、旋转给液装置(旋转头、导向器)来实现电极旋转和高压给液。电极数控进给控制技术和电火花间隙电压采集技术,经过多年发展得到了明显地提高,而由旋转装置所引起的各种问题,目前已成为了影响产品质量的主要因素。CNC electric machining small hole machine (hereinafter referred to as small hole machine) is a kind of electric discharge machine tool, which uses a continuously moving slender hollow copper tube as a tool electrode (hereinafter referred to as electrode), and passes through the medium that passes through the hole of the copper tube. (working fluid) discharges with the workpiece, and performs pulse spark discharge on the workpiece to etch the metal to achieve the purpose of perforation. This equipment is mainly used for processing microscopic holes in conductive materials such as superhard steel and cemented carbide. EDM erosion machining is the core part of CNC small hole machine. Its main functions are: 1. Adjust the feed speed of electrode processing according to the gap voltage to control the size of the discharge gap; 2. Rotary liquid supply device (rotary head, guide ) to achieve electrode rotation and high-pressure liquid feeding. Electrode numerical control feed control technology and spark gap voltage acquisition technology have been significantly improved after years of development, and various problems caused by rotating devices have become the main factors affecting product quality.

小孔机孔定位精度可以做到±1μ,而由旋转加工所引起的精度误差大于±5μ,且加工孔的形状不规则,所以旋转控制技术的创新已成为数控小孔机亟待解决的关键技术问题。The hole positioning accuracy of the small hole machine can reach ±1μ, while the accuracy error caused by the rotation processing is greater than ±5μ, and the shape of the processed hole is irregular, so the innovation of the rotation control technology has become the key technology to be solved urgently for the CNC small hole machine question.

小孔机旋转头具有电极旋转和高压给液两个功能,在微细孔(0.3~3mm直径)加工中,电极在旋转头的作用下作旋转运动,一方面可使电极端面损耗均匀,不受高压、高速工作液介质的反作用力而偏移;另一方面,高压流动的工作液在小孔壁按螺旋线轨迹流出孔外,像静压轴承那样,使电极管“悬浮”在孔心,不易产生短路,因此,电极旋转稳定性是影响小孔机加工效率和质量的重要因素。The rotary head of the small hole machine has two functions of electrode rotation and high-pressure liquid supply. During the processing of micro-holes (0.3-3mm in diameter), the electrode rotates under the action of the rotary head. The reaction force of the high-pressure and high-speed working fluid medium is offset; on the other hand, the high-pressure flowing working fluid flows out of the hole according to the helical trajectory on the wall of the small hole, like a hydrostatic bearing, so that the electrode tube is "suspended" in the center of the hole, It is not easy to produce short circuit. Therefore, the stability of electrode rotation is an important factor affecting the efficiency and quality of small hole machining.

现有旋转机构(如图1)包括步进电机(以下简称电机)、同步带、齿轮、旋转轴、轴承、电极夹头和电极。小孔机电加工属于电极与工件之间的非接触式加工,加工理想状态是电极(30cm细长空心管)沿轴向进给加工时,旋转不能有任何晃动。由于旋转轴受力、电极质量分布不匀和电极刚度有限等因素导致电极旋转时晃动较大,必须使用导向架上的导向器来限制晃动(导向器内孔直径大于电极直径),因其作用有限经常造成孔径偏大、形状不规则、表面损伤或上下段孔径偏差等严重后果。同时,由于电极晃动过大,使间隙放电失控,甚至造成电极与工件之间短路,严重影响加工质量与效率,目前小孔机旋转给液装置主要有以下不足:Existing rotating mechanism (as Fig. 1) comprises stepper motor (hereinafter referred to as motor), synchronous belt, gear, rotating shaft, bearing, electrode chuck and electrode. The electromechanical machining of small holes belongs to the non-contact machining between the electrode and the workpiece. The ideal state of machining is that when the electrode (30cm long and thin hollow tube) is fed along the axial direction, there should be no shaking when rotating. Due to factors such as the force on the rotating shaft, uneven distribution of electrode mass, and limited electrode stiffness, the electrode shakes greatly when rotating, and the guide on the guide frame must be used to limit the shake (the diameter of the inner hole of the guide is larger than the diameter of the electrode). Finite often causes serious consequences such as large aperture, irregular shape, surface damage, or deviation of upper and lower apertures. At the same time, due to the excessive shaking of the electrode, the gap discharge is out of control, and even causes a short circuit between the electrode and the workpiece, which seriously affects the processing quality and efficiency. The current small hole machine rotary liquid supply device mainly has the following shortcomings:

1、由于电极(即电极管)为细长空心、电极质量分布不匀等原因,使电极旋转时产生晃动,而导向器被动限制作用有限晃动依然存在。另外电极与导向器“接触”产生了新的阻矩,让幅度大的晃动转变成幅度小频率快、轨迹杂乱的晃动,直接影响加工孔的形状、尺寸精度和加工效率。1. Because the electrode (that is, the electrode tube) is slender and hollow, and the mass distribution of the electrode is uneven, the electrode shakes when it rotates, but the passive limiting effect of the guide still exists. In addition, the "contact" between the electrode and the guide produces a new resistance moment, which turns the large-amplitude shaking into a small-amplitude, fast-frequency, and chaotic trajectory, which directly affects the shape, dimensional accuracy and processing efficiency of the processed hole.

2、由于高压给液部件必须安装在旋转头内正上部,导致无法采用直接电机轴驱动,必须使用同步带传动。同步带压轴力在转轴上的径向载荷较大,转轴刚度(因电极必须从转轴中通过,转轴为非实心)、轴承支撑力以及同步带传动扰动等因素,都会引起电极旋转时受力不匀而出现晃动,直接影响加工孔的形状、尺寸精度和加工效率。2. Since the high-pressure liquid supply parts must be installed in the upper part of the rotary head, direct motor shaft drive cannot be used, and synchronous belt drive must be used. The radial load of the synchronous belt pressing force on the rotating shaft is relatively large, the rigidity of the rotating shaft (because the electrode must pass through the rotating shaft, and the rotating shaft is not solid), the supporting force of the bearing, and the disturbance of the synchronous belt transmission, etc., will cause the electrode to rotate. Shaking occurs evenly, which directly affects the shape, dimensional accuracy and processing efficiency of the processed hole.

3、由于拖动旋转的力矩作用在电极上部,电极本身又为细长空心,当加工端(电极下部)受到各种微小阻力扰动,其旋转运动轨迹都会发生改变,直接影响加工孔的形状、尺寸精度和加工效率。3. Since the torque of dragging and rotating acts on the upper part of the electrode, and the electrode itself is slender and hollow, when the processing end (the lower part of the electrode) is disturbed by various small resistances, its rotation trajectory will change, directly affecting the shape of the processing hole, Dimensional accuracy and processing efficiency.

4、因加工时电极在工件小孔中,无法安装监测和异常处理机构,而拖动旋转的步进电机以恒转速模式(电磁转矩自适应负载能力)运行,一旦出现电极晃动过大或“异常”接触,不仅会严重影响加工工件的质量,甚至造成整个工件报废。4. Because the electrode is in the small hole of the workpiece during processing, the monitoring and abnormal handling mechanism cannot be installed, and the stepping motor that drags and rotates runs at a constant speed mode (electromagnetic torque adaptive load capacity). Once the electrode shakes too much or "Abnormal" contact will not only seriously affect the quality of the processed workpiece, but even cause the entire workpiece to be scrapped.

5、由于电极在加工中的损耗很难预测,导致加工一定深度孔时,无法准确判断通孔是否加工完成,从而造成系统加工效率低、通孔未打穿或严重影响下一孔加工质量等后果,通孔监测一直是困扰小孔机全自动加工的技术难题。5. Due to the difficulty of predicting the loss of the electrode during processing, it is impossible to accurately judge whether the through hole is processed when processing a certain depth hole, resulting in low processing efficiency of the system, the through hole is not pierced or seriously affects the processing quality of the next hole, etc. As a result, through-hole monitoring has always been a technical problem that plagues the automatic processing of small hole machines.

上述问题多年来一直未得到有效地解决。因此,改进现有小孔机旋转加工装置,提高旋转控制及监测技术水平,解决好上述问题对数控小孔机技术进步具有重要的意义。The above-mentioned problems have not been effectively solved for many years. Therefore, improving the existing small hole machine rotary processing device, improving the level of rotation control and monitoring technology, and solving the above problems are of great significance to the technological progress of numerical control small hole machine.

发明内容Contents of the invention

本申请目的是:现有小孔机加工过程中,电极在旋转头作用下而产生旋转,当电极出现晃动时通过导向器来限制晃动幅度。由于制造业对零件精度要求越来越高,这种被动限制方法已无法满足生产需要,旋转控制技术的创新已成为数控小孔机亟待解决的关键技术问题,对此,本申请提出一种具有加工稳定性好、加工状态监测、通孔检测功能的数控小孔机电极旋转控制装置。The purpose of this application is: in the existing small hole machining process, the electrode rotates under the action of the rotating head, and when the electrode shakes, the guider is used to limit the shaking range. As the manufacturing industry has higher and higher requirements on the precision of parts, this passive limiting method can no longer meet the production needs, and the innovation of rotation control technology has become a key technical problem to be solved urgently for CNC small hole machines. In this regard, this application proposes a method with The electrode rotation control device of CNC small hole machine with good processing stability, processing status monitoring and through hole detection function.

本申请的技术方案是:The technical scheme of the application is:

一种数控小孔机电极旋转控制装置,包括步进电机,所述步进电机通过旋转头驱动电极管,还包括:A numerically controlled small hole machine electrode rotation control device, including a stepping motor, the stepping motor drives an electrode tube through a rotating head, and also includes:

带有中心孔的转子,所述转子上制有编码图形;A rotor with a central hole on which a coding pattern is made;

设于所述中心孔中的柔性的橡胶环,所述电极管插入所述橡胶环中;a flexible rubber ring arranged in the central hole, and the electrode tube is inserted into the rubber ring;

与所述转子相配合的定子;a stator cooperating with said rotor;

与所述定子相对固定、且与所述编码图形相配合以用于检测所述转子转速的线阵扫描摄像机;以及a line scan camera that is relatively fixed to the stator and cooperates with the coding pattern to detect the rotational speed of the rotor; and

为所述定子供电进而带动所述转子旋转、且与所述步进电机的电机驱动器以及所述线阵扫描摄像机均相连的驱动电路。A driving circuit that supplies power to the stator to drive the rotor to rotate, and is connected to the motor driver of the stepping motor and the line scan camera.

本申请这种数控小孔机电极旋转控制装置在上述技术方案的基础上,还包括以下优选方案:On the basis of the above-mentioned technical solution, the numerical control small hole machine electrode rotation control device of the present application also includes the following preferred solutions:

所述橡胶环的内径大于所述电极管的外径。The inner diameter of the rubber ring is larger than the outer diameter of the electrode tube.

所述橡胶环的内径比所述电极管的外径大10μm。The inner diameter of the rubber ring is 10 μm larger than the outer diameter of the electrode tube.

当然,所述橡胶环与所述电极管也可以直接接触配合。Of course, the rubber ring and the electrode tube can also be in direct contact with each other.

所述橡胶环的内孔孔壁上形成有若干凸起。Several protrusions are formed on the inner hole wall of the rubber ring.

所述转子为圆盘形结构;The rotor is a disc-shaped structure;

所述定子包括:The stator includes:

径向对称布置于所述转子上方两相对侧的第一上铁芯线圈和第二上铁芯线圈,the first upper iron core coil and the second upper iron core coil arranged radially symmetrically on two opposite sides above the rotor,

径向对称布置于所述转子下方两相对侧的第一下铁芯线圈和第二下铁芯线圈,以及a first lower iron core coil and a second lower iron core coil radially symmetrically arranged on two opposite sides below the rotor, and

布置在所述转子侧部的永久磁铁;permanent magnets arranged on the sides of said rotor;

所述第一上铁芯线圈布置在所述第一下铁芯线圈的正上方,所述第二上铁芯线圈布置在所述第二下铁芯线圈的正上方。The first upper iron core coil is arranged directly above the first lower iron core coil, and the second upper iron core coil is arranged directly above the second lower iron core coil.

所述定子还包括布置在所述转子侧部的永久磁铁。The stator also includes permanent magnets disposed at sides of the rotor.

所述橡胶环的内孔孔壁上形成有若干凸起。Several protrusions are formed on the inner hole wall of the rubber ring.

所述编码图形包括沿圆周方向均匀分布且图案各不相同的的八个图形区。The coding pattern includes eight pattern areas uniformly distributed along the circumferential direction and with different patterns.

所述步进电机的电机驱动器、所述驱动电路和所述线阵扫描摄像机均与数控小孔机的数控系统电路连接。The motor driver of the stepping motor, the driving circuit and the line scan camera are all connected to the circuit of the numerical control system of the numerical control small hole machine.

一种数控小孔机,包括上述结构的数控小孔机电极旋转控制装置。A numerically controlled small hole machine, comprising the electrode rotation control device of the numerically controlled small hole machine with the above-mentioned structure.

上述数控小孔机电极旋转控制装置的应用方法,包括:在未进行加工时,设定所述定子的线圈电流为I,随着孔深的增加,线圈电流逐渐变大,当加工孔部分导通而形成通孔时,工作液全部从通孔底部流出,此时出现突然阻力转矩变小转速变大,且调整稳定后的线圈电流与未进行加工时I的值相当,可以判定通孔已形成。The application method of the above-mentioned numerically controlled small hole machine electrode rotation control device includes: when not processing, setting the coil current of the stator to be 1, and as the hole depth increases, the coil current gradually becomes larger, and when the processing hole part conducts When the through hole is formed, all the working fluid flows out from the bottom of the through hole. At this time, the resistance torque suddenly decreases and the speed increases, and the coil current after adjustment and stabilization is equivalent to the value of I when no processing is performed. It can be determined that the through hole has been formed.

本申请的优点是:The advantages of this application are:

1、本装置依据小孔机旋转加工特点,针对细长空心电极设计了上、下两个旋转驱动支撑结构,通过高精度速度测量和控制系统调节,让“下端”旋转电极转速始终伺服跟踪“上端”旋转电极转速,从而巧妙利用旋转控制装置来补偿负载扰动,使电极旋转平稳性大幅提高,不仅确保加工孔的形状、尺寸精度,还有助于间隙放电控制和减少短路无效加工时间。利用上下两个旋转驱动来解除功能耦合,功率驱动部分由旋转头实现;导向和克服微小扰动由旋转导向控制装置完成,二者之间协同旋转巧妙地解决了电极加工稳定性问题。1. According to the characteristics of small hole machine rotary processing, this device designs two rotary drive support structures, upper and lower, for the slender hollow electrode. Through the adjustment of high-precision speed measurement and control system, the rotation speed of the "lower" rotary electrode is always servo-tracked. The upper end" rotates the electrode speed, so that the rotation control device is cleverly used to compensate the load disturbance, which greatly improves the stability of the electrode rotation, not only ensures the shape and dimensional accuracy of the machining hole, but also helps to control the gap discharge and reduce the short-circuit invalid processing time. The upper and lower rotary drives are used to release the functional coupling. The power drive part is realized by the rotary head; the guidance and overcoming the micro disturbance are completed by the rotary guide control device, and the coordinated rotation between the two subtly solves the problem of electrode processing stability.

2、此外旋转控制装置还具有加工“异常”情况检测功能。利用本专利能够提高数控小孔机加工质量和效率,具有一定的实用价值和经济效益。2. In addition, the rotation control device also has the function of detecting "abnormal" conditions in processing. Utilizing this patent can improve the machining quality and efficiency of numerical control small hole machining, and has certain practical value and economic benefit.

3、该装置还能够识别出“准”通孔出现的时刻,解决了全自动小孔机通孔检测的难题,提高了系统加工效率,避免了通孔未打穿或影响孔加工质量等后果。3. The device can also identify the moment when the "quasi" through-hole appears, which solves the problem of through-hole detection of the automatic small hole machine, improves the processing efficiency of the system, and avoids the consequences of not piercing the through-hole or affecting the processing quality of the hole. .

4、橡胶环的内径略大于电极管的外径,在一般情况下,电极管与橡胶环处于即将接触的非接触状态,橡胶环随转子同步转动,而且橡胶环的转速与电极管的转速始终保持一致。若电极管正常的小晃动,则电极管会与橡胶环轻微接触,借助橡胶环的缓冲变形吸收电极管晃动的能量,因橡胶环与电极管的转速始终保持一致,即便电极管触碰到橡胶环,也不会在电极管和橡胶环之间存在相对的周向位移,电极管并不会受到周向扭转力,在转子和橡胶环旋转导向作用下使电极管恢复正常旋转运动。4. The inner diameter of the rubber ring is slightly larger than the outer diameter of the electrode tube. Under normal circumstances, the electrode tube and the rubber ring are in a non-contact state, and the rubber ring rotates synchronously with the rotor, and the speed of the rubber ring and the speed of the electrode tube are always the same. be consistent. If the electrode tube shakes normally, the electrode tube will be in slight contact with the rubber ring, and the vibration energy of the electrode tube will be absorbed by the buffer deformation of the rubber ring. Because the speed of the rubber ring and the electrode tube is always consistent, even if the electrode tube touches the rubber ring, and there will be no relative circumferential displacement between the electrode tube and the rubber ring, and the electrode tube will not be subject to circumferential torsional force, and the electrode tube will return to normal rotational motion under the rotation and guidance of the rotor and the rubber ring.

附图说明Description of drawings

下面结合附图及实施例对本申请作进一步描述:Below in conjunction with accompanying drawing and embodiment the application is further described:

图1为本申请实施例中数控小孔机的整体原理图;Fig. 1 is the overall principle diagram of numerically controlled hole machine in the embodiment of the present application;

图2为本申请实施例中数控小孔机电极旋转控制装置的结构示意图;Fig. 2 is a schematic structural view of the electrode rotation control device of the numerical control small hole machine in the embodiment of the present application;

图3为本申请实施例中转子上编码图形的结构示意图;Fig. 3 is a schematic structural diagram of the encoding pattern on the rotor in the embodiment of the present application;

图4为本申请实施例中数控小孔机电极旋转控制装置安装支架后的结构示意图;Fig. 4 is a schematic diagram of the structure of the numerically controlled small hole machine electrode rotation control device installed with a bracket in the embodiment of the present application;

其中:1-转子,2-橡胶环,3-电极管,4-定子,401-第一上铁芯线圈,402-第二上铁芯线圈,403-第一下铁芯线圈,404-第二下铁芯线圈,405-永久磁铁,5-编码图形,501-数字图形,502-模拟图像,6-线阵扫描摄像机。Among them: 1-rotor, 2-rubber ring, 3-electrode tube, 4-stator, 401-the first upper iron core coil, 402-the second upper iron core coil, 403-the first lower iron core coil, 404-the first Two lower iron core coils, 405-permanent magnet, 5-coded graphics, 501-digital graphics, 502-analog images, 6-line scan camera.

具体实施方式Detailed ways

图1示出了本申请这种数控小孔机的一个具体实施例,与传统数控小孔机相同的是,其也包括:电极管3、步进电机、数控系统、高压给液器等等部件。其中步进电机通过旋转头(或称电极夹头)与电极管3相连以带动电极管3转动。电极管3竖直布置,旋转头位于电极管3的上端,步进电机借助同步带和同步轮驱动旋转头。Fig. 1 shows a specific embodiment of this numerically controlled small hole machine of the present application, same as the traditional numerically controlled small hole machine, it also includes: electrode tube 3, stepper motor, numerical control system, high pressure liquid feeder etc. part. Wherein the stepper motor is connected with the electrode tube 3 through a rotating head (or electrode chuck) to drive the electrode tube 3 to rotate. The electrode tube 3 is vertically arranged, the rotating head is located at the upper end of the electrode tube 3, and the stepping motor drives the rotating head by means of a synchronous belt and a synchronous wheel.

本实施例的关键改进在于还配置有数控小孔机电极旋转控制装置,参照图2所示,该装置包括转子1、定子、橡胶环2和线阵扫描摄像机6。其中:转子1带有一通孔结构的中心孔,柔软的橡胶环2固定嵌设在该中心孔中,电极管3插入橡胶环2,转子1上制有特殊的编码图形5(用以标记转子的转动角度)。定子与转子1相配合,向定子的线圈中通电而能够使得转子转动。线阵扫描摄像机6与定子相对固定,其用于扫描转子1上的编码图形5,进而检测转子1的转速。驱动电路为定子供电进而带动转子1旋转,并且驱动电路与步进电机的电机驱动器电路连接。线阵扫描摄像机6与驱动电路相连,以将其检测到的转子转速反馈给驱动电路。The key improvement of this embodiment is that it is also equipped with a CNC small hole machine electrode rotation control device, as shown in FIG. 2 , the device includes a rotor 1 , a stator, a rubber ring 2 and a line scan camera 6 . Among them: the rotor 1 has a central hole with a through-hole structure, the soft rubber ring 2 is fixedly embedded in the central hole, the electrode tube 3 is inserted into the rubber ring 2, and the rotor 1 is made with a special coding pattern 5 (used to mark the rotor rotation angle). The stator cooperates with the rotor 1, and the coils of the stator are energized to make the rotor rotate. The line scan camera 6 is relatively fixed to the stator, and is used to scan the code pattern 5 on the rotor 1 to detect the rotation speed of the rotor 1 . The driving circuit supplies power to the stator to drive the rotor 1 to rotate, and the driving circuit is connected with the motor driver circuit of the stepping motor. The line scan camera 6 is connected with the drive circuit to feed back the detected rotor speed to the drive circuit.

上述步进电机的电机驱动器、驱动电路、线阵扫描摄像机6均与该数控小孔机自身的数控系统电路连接,由数控系统统一控制三者运行状态。可见:本实施例借助数控小孔机自身的数控系统实现步进电机、驱动电路、线阵扫描摄像机6三者间的电路连接。The motor driver, drive circuit, and line scan camera 6 of the above-mentioned stepping motor are all connected to the circuit of the numerical control system of the numerical control small hole machine itself, and the operating states of the three are uniformly controlled by the numerical control system. It can be seen that in this embodiment, the circuit connection among the stepper motor, the drive circuit and the line scan camera 6 is realized by means of the numerical control system of the numerical control small hole machine itself.

本实施例中,上述转子1为圆盘形结构,其水平布置在电极管3的下端,而且最好尽可能的靠近被加工工件。In this embodiment, the above-mentioned rotor 1 is a disc-shaped structure, which is horizontally arranged at the lower end of the electrode tube 3, and preferably as close as possible to the workpiece to be processed.

上述定子包括:径向对称布置于转子1上方两相对侧的第一上铁芯线圈401和第二上铁芯线圈402,径向对称布置于转子1下方两相对侧的第一下铁芯线圈403和第二下铁芯线圈404,布置在转子1侧部的永久磁铁405。前述第一上铁芯线圈401布置在第一下铁芯线圈403的正上方,而第二上铁芯线圈402布置在第二下铁芯线圈404的正上方。The above-mentioned stator includes: a first upper iron core coil 401 and a second upper iron core coil 402 radially symmetrically arranged on two opposite sides above the rotor 1, and a first lower iron core coil radially symmetrically arranged on two opposite sides below the rotor 1 403 and the second lower iron core coil 404, the permanent magnet 405 arranged on the side of the rotor 1. The aforementioned first upper iron core coil 401 is arranged directly above the first lower iron core coil 403 , and the second upper iron core coil 402 is arranged directly above the second lower iron core coil 404 .

本实施例中,上述橡胶环2的内径最好略大于电极管3的外径,一般来说,橡胶环的内径比电极管的外径大10μm最为合适,前述的内径和外径均指直径。这样,在一般情况下,电极管3与橡胶环2处于即将接触的非接触状态(似接触而又非接触的状态),橡胶环2随转子同步转动,而且橡胶环2的转速与电极管3的转速始终保持一致。若电极管3正常的小晃动,则电极管3会与橡胶环2轻微接触,借助橡胶环的缓冲变形吸收电极管3晃动的能量,因橡胶环与电极管的转速始终保持一致,即便电极管触碰到橡胶环,也不会在电极管和橡胶环之间存在相对的周向位移,电极管并不会受到周向扭转力,在转子旋转导向作用下使电极管3恢复正常旋转运动。In this embodiment, the inner diameter of the above-mentioned rubber ring 2 is preferably slightly larger than the outer diameter of the electrode tube 3. Generally speaking, the inner diameter of the rubber ring is 10 μm larger than the outer diameter of the electrode tube. . In this way, in general, the electrode tube 3 and the rubber ring 2 are in a non-contact state (like a contact and non-contact state), and the rubber ring 2 rotates synchronously with the rotor, and the speed of the rubber ring 2 is the same as that of the electrode tube 3. The rotational speed is always the same. If the electrode tube 3 shakes normally, the electrode tube 3 will be in slight contact with the rubber ring 2, and the vibration energy of the electrode tube 3 will be absorbed by the buffer deformation of the rubber ring. When the rubber ring is touched, there will be no relative circumferential displacement between the electrode tube and the rubber ring, and the electrode tube will not be subject to circumferential torsional force, and the electrode tube 3 will return to normal rotational motion under the action of the rotor rotation guide.

之所以将橡胶环2的内径设置成略大于电极管3的外径,是为了防止橡胶环2和电极管3过紧接触而存在较大的静摩擦力,这样不利用电极管2轴向向下的进给,容易出现电极管进给卡涩的现象;同时也会导致一旦橡胶环2和电极管3的转速稍有偏差,电极管下端便受到一定的周向扭转力。The reason why the inner diameter of the rubber ring 2 is set slightly larger than the outer diameter of the electrode tube 3 is to prevent the rubber ring 2 from being in too tight contact with the electrode tube 3 and there is a large static friction force, so that the axial direction of the electrode tube 2 is not used. The feeding of the electrode tube is prone to jamming; at the same time, once the rotation speed of the rubber ring 2 and the electrode tube 3 deviates slightly, the lower end of the electrode tube will be subject to a certain circumferential torsional force.

当然,我们也可以将橡胶环内径与电极管外径设置成等值,而使得橡胶环与电极管直接轻微接触。Of course, we can also set the inner diameter of the rubber ring to the same value as the outer diameter of the electrode tube, so that the rubber ring and the electrode tube are in direct and slight contact.

上述橡胶环2的内孔孔壁上形成有众多微小的凸起,当电极管轻微晃动时这些电极管3的外壁面会触碰前述凸起。前述凸起可以是波纹状结构,也可以是阵列式点状凸起结构。这些凸起一方面是为了增加缓冲吸收,另一方面旋转导向所需力矩很小,无须较大的摩擦拖动转矩。电极管3在旋转头的作用下作旋转运动,本装置的转子与旋转头同步旋转,正常情况下转子与电极管之间无相互作用力。绝大多数晃动为非“异常”的小晃动,通过橡胶环缓冲吸收了晃动的能量,同时在转子旋转导向作用下恢复正常旋转运动;一旦出现对因电极管晃动过大造成与工件接触刮擦等“异常”时,阻力转矩会显著变大,转速迅速变小,与驱动电路相连的线阵扫描摄像机检测到该转速的变化,驱动电路立即实施停止加工并提示报警。There are many tiny protrusions formed on the inner hole wall of the above-mentioned rubber ring 2 , and the outer wall surface of these electrode tubes 3 will touch the aforementioned protrusions when the electrode tube shakes slightly. The aforesaid protrusions may be in a corrugated structure, or in an arrayed dot-shaped protrusion structure. On the one hand, these protrusions are used to increase buffer absorption, and on the other hand, the torque required for rotation and guidance is very small, and there is no need for a large frictional drag torque. The electrode tube 3 rotates under the action of the rotating head, and the rotor of the device rotates synchronously with the rotating head. Normally, there is no interaction force between the rotor and the electrode tube. Most of the shaking is not "abnormal" small shaking, the energy of the shaking is absorbed by the buffer of the rubber ring, and at the same time, the normal rotation motion is restored under the action of the rotor rotation guide; once the electrode tube shakes too much and the contact with the workpiece is scratched When it is "abnormal", the resistance torque will increase significantly, and the speed will decrease rapidly. The line scan camera connected to the drive circuit detects the change in speed, and the drive circuit immediately stops processing and prompts an alarm.

该装置的转子使用铝合金材料制造,重量很轻且为了避开中心电极管,将动力转矩由转子外围环形部分引入。具体方法如下:由数控系统中电路产生一稳定的正弦交变信号,该信号一路经功率放大后输出至励磁线圈,交变功率信号在铁芯中产生交变磁通及在转子上产生涡流;另一路信号经程控放大调整、功率放大后输出至调整线圈,也在铁芯中产生交变磁通及在转子上产生涡流。励磁线圈和调整线圈分别产生的交变磁通及涡流在转子上相互作用,形成电磁转动力矩来推动转子转动。由永久磁铁产生的磁通被转动着的转子切割时,与在转子中所产生的感应电流相互作用形成制动力矩,使转子转速保持与电信号功率成正比关系。通过D/A输出改变线圈电流来调整转速大小,电流越大转速越高。采用对称铁心线圈组是为了确保转轴径向载荷平衡,同时对称两组铁心线圈也提高了输出功率。The rotor of the device is made of aluminum alloy material, which is very light in weight and in order to avoid the center electrode tube, the power torque is introduced from the outer ring part of the rotor. The specific method is as follows: a stable sinusoidal alternating signal is generated by the circuit in the numerical control system, and the signal is output to the excitation coil after power amplification, and the alternating power signal generates alternating magnetic flux in the iron core and eddy current on the rotor; The other signal is amplified and adjusted by program control, and then output to the adjustment coil after power amplification, which also generates alternating magnetic flux in the iron core and eddy current on the rotor. The alternating magnetic flux and eddy current generated by the excitation coil and the adjustment coil interact on the rotor to form an electromagnetic torque to drive the rotor to rotate. When the magnetic flux generated by the permanent magnet is cut by the rotating rotor, it interacts with the induced current generated in the rotor to form a braking torque, so that the rotor speed remains proportional to the electrical signal power. The rotation speed is adjusted by changing the coil current through the D/A output. The larger the current, the higher the rotation speed. The use of symmetrical core coil groups is to ensure the radial load balance of the rotating shaft, and at the same time, the symmetrical two sets of core coils also increase the output power.

由于小孔加工的特殊性,只能通过转子转速来监测加工状态,因此本装置利用线阵扫描摄像机识别编码图形5,实现非接触、高精度角位移测量。具体方法如下:参照图3所示,转子1外围环形带上有两种激光直写光刻图形,一种为线状数字图形501,代表当前测量所在分区,本设计将转子分为8个分区(圆心角45度扇形为一个分区),为了让线阵传感器识别出当前测量分区,采用三条不同半径的环线进行编码,可组合出8种编码图形,其中外环线代表最高位、中环线代表次高位、内环线代表最低位,如:全无图案代表0区、三条线全有代表7区,依次类推;另一种为径角对应模拟图形502(设图形径向最长为L),在每一分区中(为绘图方便,在图3中仅在其中一个分区中画出了模拟图形),使用模拟图形方法建立角度与弧形径向长度对应映射关系,即每隔0.45度其径向长度增加L/100个长度单位,当角度增长到45度,其径向长度图形增长到L。当线阵扫描摄像机6(CCD)采集一径向线阵图像信息时,内侧三个环线点决定当前测量区域,而外侧模拟图形的径向长度对应区内的角度值,通过测量区域和区内的角度值便可精确得到绝对角度信息,而单位时间内角度变化可计算出角速度或转速。正常加工时电极管上的阻力转矩变化相对较小,一旦电极管“异常”接触工件后,阻力转矩会显著变大,转速迅速减小,所以只要快速捕获到这一信息,就能及时有效地采取相应控制策略。Due to the particularity of small hole processing, the processing status can only be monitored through the rotor speed. Therefore, this device uses a line scan camera to identify the coded pattern 5 to achieve non-contact, high-precision angular displacement measurement. The specific method is as follows: as shown in Figure 3, there are two kinds of laser direct writing lithography patterns on the peripheral annular belt of the rotor 1, one is a linear digital pattern 501, which represents the current measurement area, and this design divides the rotor into 8 areas (a sector with a central angle of 45 degrees is a partition), in order to allow the line array sensor to identify the current measurement partition, three circular lines with different radii are used for encoding, and 8 kinds of encoding patterns can be combined, in which the outer circular line represents the highest position and the middle circular line represents the second The high position and the inner ring line represent the lowest position, such as: no pattern at all represents the 0 zone, three lines all represent the 7 zone, and so on; the other is the analog figure 502 corresponding to the radial angle (the longest radial direction of the figure is L), in In each partition (for the convenience of drawing, only one of the partitions is shown in Fig. 3 for simulation graphics), use the simulation graphics method to establish the corresponding mapping relationship between the angle and the radial length of the arc, that is, every 0.45 degrees its radial The length increases by L/100 length units, when the angle increases to 45 degrees, its radial length graph increases to L. When the line scan camera 6 (CCD) collects a radial line array image information, the three inner circle points determine the current measurement area, and the radial length of the outer analog figure corresponds to the angle value in the area, through the measurement area and the area The absolute angle information can be obtained accurately, and the angle change per unit time can be used to calculate the angular velocity or rotational speed. During normal processing, the resistance torque on the electrode tube changes relatively little. Once the electrode tube "abnormally" touches the workpiece, the resistance torque will increase significantly and the speed will decrease rapidly. Therefore, as long as this information is quickly captured, the Effectively adopt corresponding control strategies.

可见,编码图形5包括沿圆周方向均匀分布而且图案各不相同的的八个图形区,每个图形区都由上述线状数字图形和模拟图形组成。It can be seen that the coding pattern 5 includes eight pattern areas uniformly distributed along the circumferential direction and with different patterns, and each pattern area is composed of the above-mentioned linear digital pattern and analog pattern.

旋转头以恒转速模式拖动电极旋转,由于各种原因电极在旋转中出现晃动,为了使电极整体保持同步旋转状态,需要对细长电极采取上下两点驱动方式,即在导向架上在安装一个旋转控制装置。通常因各种原因(如电极质量不匀等)所引起的晃动能量都较小,可以通过旋转控制装置的主动补偿来保证同步旋转状态(下转子辅助电极转速始终伺服跟踪上旋转头拖动电极管转速),方法如下:本装置采用两相步进电机,其转速可以通过脉冲频率来控制,转速计算公式(1)如下:The rotating head drives the electrode to rotate at a constant speed mode. Due to various reasons, the electrode shakes during the rotation. In order to keep the electrode as a whole in a synchronous rotation state, it is necessary to drive the slender electrode at two points up and down, that is, to install it on the guide frame. A rotary control. Usually, the shaking energy caused by various reasons (such as uneven electrode quality, etc.) is small, and the synchronous rotation state can be guaranteed through the active compensation of the rotation control device (the rotation speed of the lower rotor auxiliary electrode is always servo-tracked and the upper rotating head drags the electrode. Tube speed), the method is as follows: This device uses a two-phase stepping motor, and its speed can be controlled by pulse frequency. The speed calculation formula (1) is as follows:

Figure BDA0001601166070000091
Figure BDA0001601166070000091

其中:x:驱动器细分倍数;θ:固有步进角。Among them: x: driver subdivision multiple; θ: inherent step angle.

根据加工转速V,将对应固定频率f脉冲输入给步进电机驱动器,驱动器和步进电机拖动电极管恒转速V旋转;同时,电极管下部在旋转控制装置辅助伺服跟踪转速V,使其旋转姿态保持与上部一致,以消除上下之间的应力。这样在细长空心电极上下分别有两个旋转驱动支撑点,确保电极旋转的直线性以及补偿了各种负载扰动,保证电极旋转稳定性。According to the processing speed V, the corresponding fixed frequency f pulse is input to the stepper motor driver, and the driver and the stepper motor drive the electrode tube to rotate at a constant speed V; at the same time, the lower part of the electrode tube assists the servo tracking speed V in the rotation control device to make it rotate Stance remains consistent with the upper to eliminate stress between the upper and lower. In this way, there are two rotating driving support points on the upper and lower sides of the elongated hollow electrode, which ensures the linearity of the electrode rotation and compensates for various load disturbances, ensuring the stability of the electrode rotation.

电极管的加工转速不高(20~120转/分),加工时旋转头工作在恒转速模式,但为了保证启动或换挡时旋转控制装置的协同跟踪稳定性,步进电机必须按照设定的升、减速曲线调速。The processing speed of the electrode tube is not high (20-120 r/min), and the rotating head works in the constant speed mode during processing. However, in order to ensure the coordinated tracking stability of the rotation control device when starting or shifting, the stepper motor must follow the set Acceleration and deceleration curve speed regulation.

加工端引起的扰动主要有以下几种:未加工时由于两点驱动支撑,电极空载晃动几乎没有,当电极在下降接触电极瞬间,接触力和放电力作用导致转速异常,由旋转控制装置检测并迅速回退电极,避免工件孔的损坏。之后再以低速下降开始正常加工;正常加工时随着加工深度的增加,工作液对电极管壁的压力也逐渐增加,这时数控系统根据转速地变化,不断地调整线圈电流以保持转子的恒转速V;正常加工时放电力及工作液的反作用力形成的扰动,也会因旋转控制装置的作用而抵消;当电极管头破裂或其它原因使旋转电极与工件“异常”接触,均会导致阻力转矩显著变大,转速迅速变小,此时数控系统会立即关闭旋转和高频电源、迅速回退电极,避免造成工件报废的严重后果。The disturbances caused by the processing end mainly include the following types: due to the two-point drive support during unprocessed, there is almost no no-load shaking of the electrode. When the electrode is falling and touching the electrode, the contact force and discharge force cause abnormal speed, which is detected by the rotation control device. And quickly withdraw the electrode to avoid damage to the workpiece hole. After that, the normal processing starts with a low speed drop; during normal processing, as the processing depth increases, the pressure of the working fluid on the electrode tube wall also gradually increases. Speed V; the disturbance caused by the discharge force and the reaction force of the working fluid during normal processing will also be offset by the action of the rotating control device; when the electrode tube head is broken or other reasons make the rotating electrode contact with the workpiece "abnormally", it will cause The resistance torque increases significantly, and the speed decreases rapidly. At this time, the numerical control system will immediately turn off the rotation and high-frequency power supply, and quickly retract the electrode to avoid serious consequences of scrapping the workpiece.

在小孔机深孔加工时,通常用补偿方法来设定加工深度,但因电极管损耗受加工材料等因素影响而无法精确计算,实际加工中经常出现通孔未打穿(盲孔),而为了避免这种现象出现,操作者必须加大深度补偿,这又致使多数孔打穿后,数控系统坐标并未达到设定深度,造成继续“空打”一段深度的情况。因数控小孔机主要用于批量孔加工,这种情况严重影响加工效率。本装置用于通孔检测方法如下:在未进行加工时,旋转控制装置线圈电流(也即定子线圈的电流)为I,随着孔深的增加线圈(定子线圈)电流会逐渐变大,当加工孔部分导通而形成“准”通孔时,液体(即工作液)全部从孔底部流出,此时会出现突然阻力转矩变小转速变大,且调整稳定后的线圈电流与未进行加工时I的值相当,可以判定“准”通孔已形成,数控系统及时发出开启辅助给液电磁阀命令,由外给液管为加工孔补给工作液,保证了“准”通孔加工至通孔阶段的加工质量。In the deep hole machining of small hole machines, the compensation method is usually used to set the machining depth, but the loss of the electrode tube is affected by factors such as the machining material and cannot be accurately calculated. In actual machining, the through hole is often not pierced (blind hole). In order to avoid this phenomenon, the operator must increase the depth compensation, which causes the coordinates of the CNC system to not reach the set depth after most holes are pierced, resulting in the situation of continuing to "dry" a certain depth. Because the CNC small hole machine is mainly used for batch hole processing, this situation seriously affects the processing efficiency. This device is used for the through-hole detection method as follows: when not processing, the rotation control device coil current (that is, the current of the stator coil) is 1, and the coil (stator coil) current will gradually increase along with the increase of the hole depth, when When the processed hole is partially conducted to form a "quasi" through hole, the liquid (that is, the working fluid) will all flow out from the bottom of the hole. At this time, the resistance torque will suddenly decrease and the speed will increase. The value of I is the same during processing, so it can be judged that the "quasi" through hole has been formed, the numerical control system sends out the command to open the auxiliary liquid supply solenoid valve in time, and the working fluid is supplied to the processing hole from the external liquid supply pipe, ensuring that the "quasi" through hole is processed to Processing quality at the through-hole stage.

当然,上述实施例只为说明本申请的技术构思及特点,其目的在于让人们能够了解本申请的内容并据以实施,并不能以此限制本申请的保护范围。凡根据本申请主要技术方案的精神实质所做的等效变换或修饰,都应涵盖在本申请的保护范围之内。Certainly, the above-mentioned embodiments are only for illustrating the technical conception and characteristics of the present application, and the purpose is to enable people to understand the content of the present application and implement it accordingly, and not to limit the protection scope of the present application. All equivalent changes or modifications made according to the spirit of the main technical solutions of this application shall fall within the scope of protection of this application.

Claims (8)

1. The utility model provides a numerical control is little Kong Jidian utmost point rotary control device, includes step motor, step motor passes through swivel drive electrode tube (3), its characterized in that still includes:
a rotor (1) with a central hole, wherein a coding pattern (5) is manufactured on the rotor (1);
a flexible rubber ring (2) arranged in the central hole, wherein the electrode tube (3) penetrates into the rubber ring (2);
a stator cooperating with the rotor (1);
a linear array scanning camera (6) which is relatively fixed with the stator and is matched with the coding pattern (5) for detecting the rotating speed of the rotor (1); and
the driving circuit is used for supplying power to the stator so as to drive the rotor (1) to rotate and is connected with a motor driver of the stepping motor and the linear array scanning camera (6);
the rotor (1) is of a disc-shaped structure;
the stator includes:
a first upper core coil (401) and a second upper core coil (402) which are radially symmetrically arranged on two opposite sides above the rotor (1),
a first lower core coil (403) and a second lower core coil (404) which are radially symmetrically arranged on opposite sides below the rotor (1), and
a permanent magnet (405) arranged on the side of the rotor (1);
the first upper core coil (401) is arranged directly above the first lower core coil (403), and the second upper core coil (402) is arranged directly above the second lower core coil (404);
the motor driver of the stepping motor, the driving circuit and the linear array scanning camera (6) are all connected with a numerical control system circuit of the numerical control pinhole machine.
2. The numerical control small Kong Jidian pole rotation control device according to claim 1, wherein the inner diameter of the rubber ring (2) is larger than the outer diameter of the electrode tube (3).
3. The numerical control small Kong Jidian pole rotation control device according to claim 2, wherein the inner diameter of the rubber ring (2) is 10 μm larger than the outer diameter of the electrode tube (3).
4. A numerical control small Kong Jidian pole rotation control device according to claim 1, characterized in that the rubber ring (2) is in contact fit with the electrode tube (3).
5. The numerical control small Kong Jidian pole rotation control device according to claim 2, 3 or 4, wherein a plurality of protrusions are formed on the inner hole wall of the rubber ring (2).
6. The numerical control small Kong Jidian pole rotation control device according to claim 1, wherein the code pattern (5) includes eight pattern areas uniformly distributed in the circumferential direction and having different patterns.
7. A numerical control small hole machine, characterized by comprising the numerical control small Kong Jidian pole rotation control device according to any one of claims 1 to 6.
8. A method of using the numerical control small Kong Jidian pole rotation control device according to any one of claims 1 to 6, wherein the coil current of the stator is set to I when the machining is not performed, the coil current is gradually increased with an increase in the hole depth, and when the machining hole is partially conducted to form the through hole, the working fluid is entirely discharged from the bottom of the through hole, and the abrupt resistance torque reduction and the rotation speed increase occur at this time, and the coil current after the adjustment is stabilized is equivalent to the value of I when the machining is not performed, so that it can be determined that the through hole has been formed.
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