How to set electrical parameters correctly for DK77 series wire cutting machine?

DK77 Series CNC Wire Cutting Machine (Mechanical and Electrical Parts) Table of Contents I. Overview II. Main Technical Parameters III. Machine Transmission System IV. Under the control of the control system, the workpiece is processed according to the pre-set trajectory. Wire-cutting machine tool is suitable for processing all kinds of molds, cutting micro-precision and complex shape parts and samples, cutting tungsten and silicon wafers and so on. Widely used in machinery, electronic and electrical fields. Main Technical Parameters The main technical parameters are shown in Table I. Table I main technical parameters Model DK7725 series DK7732 series DK7740 series Table size 640 mm × 460 mm 880 mm × 540 mm 900 mm × 550 mm table travel 320 mm × 250 mm 420 mm × 320 mm 480 mm × 400 mm Maximum thickness of the cutting ordinary adjustable wire frame for 300 mm, taper adjustable wire frame for 250 mm. Taper adjustable wire frame 250 mm Maximum cutting taper 6 ° Maximum cutting speed >120mm 2 /min Roughness of machined surface Ra ≤ 2.5μ m (20mm 2 /min) Electrode wire diameter φ 0.10 mm - φ 0.19mm Protective function Automatic shutdown of the wire traveler when the wire is disconnected Power supply Single-phase 220V 50Hz Power consumption & lt; 1 KW Size of machine lt; 1 KW Machine size 1400mm×1150mm×1600mm 1400 mm×1300 mm×1600 mm Third, the machine tool transmission system The mechanical part of the machine tool is mainly composed of bed, table, wire transportation device, wire frame, cooling system, fixture, waterproof cover and other components. Transmission system diagram is shown in Figure I. Rolling bearings, motor type and specification are shown in Table II. 3 Fig. 1 Transmission system diagram Wire storage cylinder Wire discharge wheel Conductive block Upper guide wheel Cutting area Conductive block Lower guide wheel Conductive block Fig. 1 Transmission system diagram 4 Table 2 Rolling bearings and motors Model specifications No. Name Model No. Specification Accuracy Quantity Mounting position Z1 Bearing D204 E 2 Silk cylinder Wire transportation Z2 Bearing D204 D 2 Silk cylinder Z3 Bearing D203 C 1 Drag board screw Z4 Bearing D36105 C 2 Drag board screw Z5 Bearing D36105 C 2 Drag board screw Z5 Bearing D36105 C 2 Drag board screw D36105 C 2 Drag board screw D36105 C 2 Drag board screw D36105 C 2 Drag board screw Z5 bearing D36105 C 2 Trailer Screw Z6 Bearing D24 D 2 Spool Z7 Bearing D24 D 4 Guide Wheel Z8 Bearing D204 D 2 Cylinder Z9 Bearing D203 C 1 Trailer Screw M DC permanent magnet motor 110SYT51 110V/2.5A 1 Cylinder MX Stepper Motor 75BC003 30VDC/4A 1 Trailer Screw MY Stepper Motor 75BC003 30VDC/4A 1 Trailer Screw 30VDC/4A 1 drag plate screw Single-phase electric pump Single-phase 220V 1 water tank 1, the transmission process of the table: X direction: the control system sends out the feed pulse → → X-axis stepping motor MX → → gears 6 / gears 5 → → screw CX → → → nut LX → → → lower drag plate; Y direction: the control system sends out the feed pulse → → → Y-axis stepping motor MY → → → gears 7 / gears 8 → → → → screw CY → → nut LY → upper drag plate; Y direction: the control system sends out the feed pulse → → → Y-axis stepping motor MY → → → gears 7 / gears 8 → → → → screw CY Nut LY→→upper drag plate; every pulse sent out by the control system, the table drag plate moves 0.001mm; in addition, two hand cranks in X and Y directions can also make the table move in X and Y directions. 2, the transmission process of the wire transport device: wire transport motor M → → → → coupling → → → storage cylinder high-speed rotation → → → gear 4 / gear 3 → → → gear 2 / gear 1 → → silk rod C → → → nut L → → → → travel switch; wire transport device drives the electrode wire according to a certain linear speed movement, through the wire frame of the wire wheel, guide wheel will be the electrode wire in the storage cylinder neatly arranged around the travel limit switch to control the storage cylinder of forward and reverse rotation. Fourth, the machine tool electrical system The electrical schematic diagram of the machine tool is shown in Figure 2, in line with the relevant national standards. Machine and controller, high-frequency power supply, stepping power supply connection interface see Figure III. Machine electrical operation panel schematic diagram in Figure IV. The power supply of the machine tool is single-phase 220V/50H. The three-core power socket of the machine tool is grounded according to the standard, and it is forbidden to connect the grounding chip of the power supply socket with the neutral wire of the power supply. The lighting specification is 24V/40W. The list of electrical components of the machine tool is shown in Table III. 5 Figure 2 Electrical schematic diagram of the machine 6 Figure 3 Connecting interface Figure 4 Operation panel As shown in Figure 5, install the machine, connect the power cord, close the gate, you can operate the machine. A connected interface 1, high-frequency power supply + 6, stepping motor drive power + 2, high-frequency power supply - 7, 8, 9 stepping motor X-axis 3, high-frequency sampling + 10, 11, 12 stepping motor Y-axis 4, the empty foot 13, off the high-frequency relay contact 5, high-frequency sampling - 14, off the high-frequency relay contact B connected interface 1, high-frequency power supply + 6, stepping motor drive power - 14, off high-frequency relay contact ＋ 6, stepper motor drive power supply + 2, high-frequency power supply - 7, 8, 9 stepper motor U-axis 3, high-frequency sampling + 10, 11, 12 stepper motor V-axis 4, foot 13, off the high-frequency relay contact 5, high-frequency sampling - 14, off the high-frequency relay contact 12 11 10 14 13 5 9 4 8 7 1 3 6 2 6 10 9 1 2 4 11 14 12 8 5 13 7 3 Fig. 4 Operation Panel Diagram 1 2 3 4 Threading Liquid Pump Speed Adjustment 100 0 50 1 5 0 V Threading Voltage SB1 SB3 SC SB2 SB4 Threading Open Button Liquid Pump Open Button Threading Close Knob Liquid Pump Close Button Threading Speed Adjustment Knob Note: SB1 knob indicates pointing to the right, the silk cylinder motorized machine, and at the same time the silk cylinder loses the braking force; recovery knob indicates pointing to the left, the silk cylinder to restore braking force. Recovery knob indication points to the left, the silk cylinder to restore braking power. 7 Fig. 5 Layout of the machine installation 1, set the "silk speed adjustment" knob SC to 1, so that the silk cylinder runs slowly, ready for the silk before loading. 2, use a large screwdriver to thread the silk cylinder. 2, with a larger screwdriver in the molybdenum wire disk bore, the molybdenum wire end from the wire frame row wheel → upper guide wheel → lower guide wheel → the lower side of the storage cylinder through, fixed in the left side of the storage cylinder screws. Press SB2, the wire storage cylinder will run, and the wire will start to be loaded. Rotate the "thread closing knob" SB1 to the right and return it to the original position, the thread motor will stop with brake and the thread loading will be finished. Fig. 6 Schematic diagram of bumping block and travel switch Fig. 7 Schematic diagram of wire frame Fig. 5 Distribution board of machine tool power supply line power line controller pulse power supply stepping power supply 14-core connecting wire machine tool 1 4 0 0 0 1150 4 0 0 0 600 greater than 1 0 0 0 0 0 greater than 600 Operator's position 8 3. Set the "wire speed adjustment" knob SC to 2 or 3 or 4 speeds, and the wire cylinder will run. Set the "Wire Speed Adjustment" knob SC to 2 or 3 or 4, and the "Wire Run Voltage" will be about 110V when the cylinder is running. Adjust the left and right blocks SL and SR on the block holder of the cylinder (see Figure 6: Schematic diagram of block and travel switch), so that the molybdenum wire wound on the storage cylinder will be reversed by depressing SQ2 or SQ3 when it is about to be wound. 4, when the travel limit switch SQ2 and SQ3 are not pressed, press the "go silk open button" SB2, the wire transport motor M positive rotation, the silk cylinder to the direction away from the operator (i.e., to the rear side of the machine tool) running; running to the right bump SR pressed down the travel limit switch SQ3, the wire transport motor M reversal, the silk cylinder to close to the operator direction running, until the left bump SL pressed down the travel limit switch SQ3, until the left bump SL pressed down the travel limit switch SQ3, the wire transport motor M reversed, the silk cylinder to the direction close to the operator running When the right ram SR depresses the travel limit switch SQ3, the thread transport motor M reverses and the thread cylinder runs in the direction close to the operator. 5. Rotate the "silk off knob" SB1 to the right, the silk cylinder motor stops running; at this time, the SB1 knob indication points to the right, there is no braking force of the silk cylinder, the SB1 knob indication is restored to the left, and the silk cylinder stops rotating quickly under the action of braking force. 6, press the "liquid pump open button" SB4, saponification liquid pump operation; added to the processing workpiece working fluid flow size, controlled by the valve located on the wire frame. Press the "liquid pump off button" SB3, saponification liquid pump stop running. 7, due to accidental reasons, the wire transport motor M can not be reversed, the left and right bumpers SL, SR punch through the SQ2 or SQ3 will be pressed down the SQ1 travel limit switch, the machine tool stops. 8. The machine has a protection function of stopping the wire transportation motor after breaking the wire. After wire breakage, the upper arm of the wire frame picks up the wire breakage signal at T1 (see Figure 1: Schematic diagram of the transmission system), which drives the wire breakage protection relay to work and cuts off the main power supply. When the molybdenum wire is too loose, use the molybdenum wire tensioning wheel to pick up the molybdenum wire for tightening operation, the molybdenum wire disengages from the T1 point, the wire breakage relay operates, and the wire transportation motor M stops, which is a normal phenomenon. Keep the molybdenum wire tensioning state, press the "go silk open button" SB2, silk cylinder rotation, continue tightening operation. Table III list of electrical components of the machine No. Code Name Specification Model Quantity Remarks 1 TC control transformer JBK-500 220V/110V/? /24V/12 1 2 KM1-3 AC contactor JZC1-44 (3TH82 44) AC/110 3 3 K1 Relay JTX /AC 110V 1 Shangwu Bafang 4 K2 DC relay HG4137 012-2Z-1 1 5 SQ1-3 Limit switch AZ 7311 3 6 SB1 Knob switch LA18 380V 1 7 SB2-4 Push button switch LA19 380V 3 8 SC Rotary Tab Switch KX04 5W2D 1 9 FU1-2 Fuse RL1-15 380V 5A 2 10 R1 Resistor RX-75-10Ω ±5% 1 11 R2 Resistor RJ-3-5.1Ω ±5% 1 12 R3 Resistor RJ-0.25-5.1K ±5% 1 13 R4 Resistor RJ-0.25-100Ω ±5% 1 13 C1 Capacitor CBBB-1012-2Z-1 1 14 SQ1-3 Limit Switch AZ 7311 3 6 SB1 Rotary Switch AZ 7311 1 14 C1 Capacitor CBB22 1μ F 400V 1 15 C2 Electrolytic Capacitor CD11-25V-1000μ F 1 16 C3 Electrolytic Capacitor CD11-25V-1000μ F 1 17 C4 Electrolytic Capacitor CD11-16V-470μ F 1 18 V Transistor C 9013 1 19 VC Bridge Rectifiers KBPC 3510 1 20 VS Voltage Regulators BZX55C 6.8V 1 21 VT1-2 Diode IN 4007 2 9 V. MACHINE TOOL INSTALLATION, ADJUSTMENT AND OPERATION (1) Installation 1. When lifting the machine tool, fix the wire rope with sufficient strength for lifting to the lifting rings at the four corners of the bed body, and the length and angle should be appropriate to avoid contact with the machine tool parts and to prevent damages to the machine tool appearance and accuracy. Avoid tilting and impact during the whole transportation process. Recommended use of forklifts to load and unload, handling machine tools. 2、 Refer to Fig. 5 for the installation layout of the machine tool, and take the convenience of operation as the first priority. With the help of the bed below the four horizontal adjustment screws will be adjusted to the level of the machine table, so that the level meter on the table surface of the vertical and horizontal readings of the difference of 0.04? (B), wire frame adjustment wire frame view in Figure VII. 1, wire frame height adjustment: According to the thickness of the workpiece processing to select the appropriate height of the wire frame (DK7725B, DK7732B, DK7738B). Loosen the screws MA, MB on the cantilever arm of the wire frame, loosen the fastening nut of the screw S, and rotate the screw S with the plate hand to adjust the height of the wire frame to the desired height. 2. Molybdenum wire verticality adjustment: Use the vertical block to correct the molybdenum wire vertically. If the molybdenum wire is not perpendicular to the table surface in the X direction, loosen the screws MA, MB, and then screw M1-M4 to adjust the perpendicularity of the molybdenum wire with the table surface in the X direction, and then tighten the screws MA, MB; if the molybdenum wire is not perpendicular to the table surface in the Y direction, adjust the upper and lower guide wheels left and right to adjust the perpendicularity of the molybdenum wire with the table surface in the Y direction. (C) Operating steps 1, the preparation of the processing program into the controller. 2, press the "walk the wire open button", the silk cylinder operation; press the "liquid pump open button", the liquid pump work; open the controller power switch; open the stepping power supply power switch; open the pulse power supply power switch. 3, press the controller in the "feed" key, the controller panel XY axis status indicator light, check whether the worktable hand crank suction, observe the scale value of the dial relative to the "0" bit of the engraved line there is no looseness (if there is looseness, will be corresponding to the axis of the fastening stepper motor screws loose, put the stepper power supply power switch. If there is any looseness, loosen the screw of the stepping motor of the corresponding axis, lean the stepping motor to the direction of the screw, so as to reduce the clearance of the gear 5/gear 6 or the gear 7/gear 8 (in order to shake the handle not to feel tight as a criterion), and then tighten the tightening screws. 4、 Adjust the working fluid switch on the wire rack column, so that the upper and lower nozzles of water out of the normal size. 5, press the controller in the "processing", "high-frequency" key, adjust the pulse power supply and the controller state, that is, you can start cutting and processing, due to the thickness of the workpiece, the material is different, the normal processing current stabilized at 0.5-2.5A. -6, after processing, the first off the pulse power supply, stepping power, and then off the machine fluid pump and silk cylinder. Sixth, the lubrication of the machine tool The moving parts of the machine tool are lubricated by manual lubrication on a regular basis. Upper and lower drag plate of the screw, transmission gears, bearings, rails, silk cylinder of the screw, transmission gears, bearings, rails should be lubricated every day with oil gun refueling lubrication, lubricating oil model HJ-30 mechanical oil. When refueling to shake the handle or rotate the silk cylinder by hand, so that the silk rod, guide rail throughout the movement. Before refueling the guide wheel, row of wheel bearings, the guide wheel, row of wheel kerosene should be cleaned with kerosene and then oil, refueling period of every three months. Seven, the maintenance of the machine tool 1, the machine should be kept clean, more than 8 hours of downtime should be wiped clean and coated with oil to prevent rust. 2, the conductive block on the wire frame, wire wheel, around the guide wheel and the gap between the two ends of the storage cylinder should be cleaned often with kerosene, after cleaning the dirty oil should not flow back to the table in the return tank. 3, molybdenum wire electrode and the insulation between the workpiece is guaranteed by the workpiece fixture, the conductive block, the workpiece fixture should be often wiped clean of insulating materials to ensure insulation requirements. 4, guide wheel, wire wheel and bearings generally use 6-8 months should be replaced in sets. 5, from time to time to check the silk cylinder motor M carbon brushes, rotor, found that the carbon brushes are badly worn or rotor dirt, should replace the carbon brushes or clean the rotor. 10 6, the working fluid circulation system should be unblocked in time, especially to prevent the working fluid from penetrating into the machine and causing electrical failure. 7, replace the travel limit switch, the need to re-adjust the bump bump, the principle of adjustment is: to ensure that 0.5-1mm over-travel, over-travel is too small is not reliable enough action, over-travel is too large is easy to damage the travel switch. 8, the machine should be isolated from outside sources of vibration, to avoid strong electromagnetic fields nearby, the entire work area to maintain a clean. 9, when the supply voltage exceeds the rated voltage ± 10%, it is recommended to use a regulated power supply. VIII. Common failure Because of the wire-cutting machine tool has a lot of devices are high-speed operation and close contact with the moving objects, there is a certain life expectancy. After a period of normal operation of the machine tool, the wear and tear of these devices will lead to a failure of the machine tool, which should be replaced. The list of wearing parts is shown in Table IV. Table IV List of wearing parts No. Name Quantity Location Wear, damage to the main symptoms Remarks 1 Front and rear guide wheels 2 upper and lower wire arms Poor roughness, molybdenum wire jumping, low efficiency 2 D24 guide wheel bearings 2 upper and lower wire arms Poor roughness, molybdenum wire jumping, low efficiency 3 conductive block 2 upper and lower wire arms molybdenum wire is deep, easy to pull off 4 Cylinder motor carbon brushes 2 in the motor Motor does not rotate, scratches the commutator Normal checking 5 Cylinder couplings Rubber 1 Abnormal sound during commutation between motor and cylinder 6 Upper and lower spigots 2 Upper and lower wire arms Incorrect flow of machining fluid 7 Travel limit switch 3 Abnormal commutation of bed Common faults are listed in Table 5. Table 5 List of common faults Fault phenomenon Fault reason Remedy 1. The storage cylinder does not change direction, causing the machine to stop. The travel switch SQ3 or SQ2 is damaged. Change the travel switch SQ3 or SQ2. 2. The wire storage cylinder often stops when changing direction. Electrode wire is too loose; 2. Failure of the protection circuit of broken wire. 1, tight electrode wire; 2, change the broken wire protection relay. 3、Silk cylinder does not rotate (no reaction when pressing the button SB1). 1, the external power supply voltage; 2, resistance R1 burned; 3, bridge rectifier VC damage, resulting in fuse FU1 fuse. 1, check the external power supply and exclude; 2, replace the resistor R1; 3, replace the rectifier VC, fuse FU1. 4, the silk cylinder does not rotate (walking wire voltage is indicated and higher than the normal work). 1, carbon brush wear or rotor dirt; 2, motor M power feed line broken. 1, replace the carbon brush, clean motor rotor; 2, check the feed line and exclude. 5, the work light does not light. Fuse FU2 is broken. Replace fuse FU2. 11 6, the working fluid pump does not turn or slow speed. 1, the liquid pump work contactor KM3 does not absorb; 2, the work of the liquid pump capacitance damage or capacity reduction; 1, press SB4, KM3 wire pack two ends if there is 115V voltage, then replace the KM3, if there is no 115V voltage, check the control of the KM3 wire pack circuit; 2, change the same specification capacitance or and a capacitor with sufficient voltage resistance 7, the high-frequency power supply is normal, go normal, no high-frequency sparks (simulation operation is normal) (cutting does not go). 1, if the high-frequency relay K1 does not work, it is the travel switch SQ3 normally closed contacts bad; 2, if the high-frequency relay K1 can be absorbed, it is the high-frequency relay contacts bad or high-frequency output line break. 1, change the travel switch SQ3; 2, change the high-frequency relay K1, check the high-frequency power output line, and exclude open-circuit faults.