中英文DK77系列數(shù)控電火花線切割機床使用說明書

1、. . . . 封面：DK77 Series NC EDM Wire-Cutting Machine ToolDK77系列數(shù)控電火花線切割機床Use Description使用說明書Ningbo Zhongyuan Machine Tool Co., Ltd. 中原機床Catalogue目錄Machine Tool Use機床用途Machine Tool Features機床特點Main Use主要用途Structure and Principle of Operation工作原理與結(jié)構(gòu)Principle of Operation工作原理Mechanical System Structure機

2、械系統(tǒng)結(jié)構(gòu)Technical Parameters技術(shù)參數(shù)Characteristic Model Stipulations特性型號的規(guī)定Basic Parameters基本參數(shù)Machine Tool Handling and Installation機床的搬運與安裝Machine Tool Handling and Hoisting機床的搬運與吊裝Machine Tool Installation機床的安裝Machine Tool Adjustment and Operation機床調(diào)整與操作Preparation Works準備工作Coil Holder Adjustment線架調(diào)整Wo

3、rktable Regulation工作臺調(diào)整Kinetic Wire Component Adjustment and Electrode Wire Coiling運絲部件調(diào)整與電極絲繞裝Guide Wheel Adjustment導輪的調(diào)整Work-Piece Clamping工件裝夾Operation and Points for Attention操作與注意事項Machine Tool Maintenance and Trouble Removal機床的維護與故障的排除Machine Tool Maintenance機床的維護Common Troubles and Removals o

4、f the Machine Tool機床的常見故障與排除Vulnerable Part Table易損零件表Machine Tool Running System Installation and Use Description機床電器安裝與使用說明Summary of Machine Tool Running System and Control System電器控制系統(tǒng)概述Common Troubles of Machine Tool Running System: Causes and Removals電器常見故障：原因與排除Safety Protection Measures of M

5、achine Tool Running System機床電器安全保護措施Schematic Drawing of 25V Drive Head Mains 25伏驅(qū)頭電源原理圖Schematic Drawing of Machine Tool Running System機床電器原理圖DK77 SeriesDK77系列Use Description of Machine Tool機床使用說明書38 Pages Total共38頁Page 1第一頁Machine Tool Use機床用途Machine Tool Features機床特點Max. feature of this serial pr

6、oduct lies in the fact that it has no special requirements to the processed metal material properties. In principle, it can process all the conductive materials such as super-hard and hard alloy, quenching materials, stainless steel ductile materials, various magnet steel fragile materials, uneasily

7、-clamped thin wall spares etc. If the Machine Tool gets the aid of the auxiliary extra-large specification of “Taper Cutting Device” and “Responsive Micro-Computer System” produced by this Company, then it can gain the satisfactory results in processing all kinds of thespecial spares which terrify o

8、ther Machine Tools. Following theconstant appearance of the high-tech products, it continuously prospers the national economy. We predict that the characteristics of this serial product will be further developed and utilized. It will find favor in the eyes of vast customers.本系列產(chǎn)品最大特點是對被加工的金屬材料性質(zhì)無特殊要

9、求，原則上凡導電材料均可加工。如超硬、硬質(zhì)合金、淬火材料；如不銹鋼類的韌性材料；各類磁鋼的脆性材料；不易裝夾的薄壁零件。若機床輔以本公司制造的特大規(guī)格錐度切割裝置與響應(yīng)微機系統(tǒng)，那么對其他機床望而生畏的各種特異零件加工都能取得令人滿意的效果。隨著高科技產(chǎn)品不斷出現(xiàn)，國民經(jīng)濟的不斷繁榮，我們預言，本系列產(chǎn)品的特點將進一步得到開發(fā)利用，受到各位客戶的歡迎。Main Use主要用途It processes various molds such as rubber and plastic molds, punch die and so on.加工各類模具：橡塑模、沖模等等。It processes t

10、he special materials of fragile materials, stainless steel ductile materials, super-hard materials.加工特殊材料：脆性材料、不銹鋼韌性材料、超硬材料。It processes the complex-shape spares such as the tapered upper and lower specially-shaped spares and so forth.加工復雜形狀零件：帶錐度的上下異形零件等。Structure and Principle of Operation工作原理與結(jié)構(gòu)P

11、rinciple of Operation工作原理The serial product applies “Electrical Discharge Machining” mechanism. It gets the auxiliary aid from electro-mechanically integrated product which combines Automated Controlwith Micro-Computers. The Machine Tool usually adopts “Molybdenum Wire” or “Hard Brass Wire” as the “

12、Tool Electrode”. Under the “High Frequency Pulse Voltage Functions”, it utilizes the effect that it forms “Spark Discharge” after the liquid medium has been broken down. It instantaneously produces great volumes of heat energy in the Spark Channel. It melts or even gasifies the metal in the surface

13、of the Work-Piece. With the joint action of the liquid medium, the metal has been rapidly eroded and removed. The Work-Piece which has been chucked in the coordinates Work-Table has been processed into various required shapes according to the pre-formulated program under the Micro-Computer Control.本

14、系列產(chǎn)品是應(yīng)用“放電加工”機理，輔以自動控制與微機相結(jié)合的機電一體化產(chǎn)品。機床通常采用鉬絲或硬性黃銅絲作為工具電極，在高頻脈沖電壓作用下，利用液體介質(zhì)被擊穿后形成火花放電，在火花通道中瞬間產(chǎn)生大量的熱能，使工件表面的金屬熔化甚至氣化，加上液體介質(zhì)的共同作用，而使金屬被迅速蝕除下來。裝夾于座標工作臺上的工件在微機控制下按預行編制的程序被加工出各種所需的形狀。Please Refer to Diagram 1 for its Basic Composition其基本組成見圖1File文件Programming編程Reader輸入機Power Amplification功放Micro-Compute

15、r微機Variable Frequency變頻Detection檢測Calculation System運算系統(tǒng)Step-Motor步進電機Machine Tool機床Pulse Mains脈沖電源Diagram 1圖1Machine Tool Composition Diagram機床組成方框圖Page 2第二頁We can see from the above diagram that the whole system is composed of the “Computer System”,“Machine Tool Control System”, “Mechanical System

16、”. The Processing Documents” form “Computer-Input Machine Tool Control System” through programming. The “Control System” controls the “Machine Tool” to complete the program actions and therefore finishes the Processing Instructions. The “Mechanical System” is based upon the “Machine Tool Body”. It i

17、ncludes the “Coordinates Work-Table”, “Kinetic Wire System”, “Cooling System”.由上圖可見整個系統(tǒng)主要由計算機系統(tǒng)、機床控制系統(tǒng)和機械系統(tǒng)組成。加工文件通過編程形成計算機輸入機床控制系統(tǒng)，并由控制系統(tǒng)控制機床完成程序的動作，以此完成加工指令。機械系統(tǒng)以床身為基礎(chǔ)，包括坐標工作臺、運絲系統(tǒng)、冷卻系統(tǒng)。The “Micro-Computer System” allocated by this Machine Tool is a new generation “Control System”. For details, pl

18、ease refer to “Use Description and Machine Tool Running System Parts”. It mainly consists of the Micro-Computer with the collocation of “Special-Purpose Interpolating Control Software”, “Interface Circuit”, “Stepping Drive Circuit”. It has the sound operationality because of the adoption of the adva

19、nced CNC technology. 本機所配的微機系統(tǒng)是新一代的控制系統(tǒng)，詳見使用說明書、電器部分。其主要由微機配上專用的插補控制軟件與接口電路和步進驅(qū)動電路組成，由于采用了先進的CNC技術(shù)，所以具有良好的操作性。Mechanical System Structure機械系統(tǒng)結(jié)構(gòu)The Mechanical System Part of this “Machine Tool” is composed of the key elements such as the “Machine Tool Body”, “Work-Table”, “Kinetic Wire Device”, “Coil

20、 Holder” (including Taper Device), “Cooling System” etc.本機床的機械系統(tǒng)部分由床身、工作臺、運絲裝置、線架（包括錐度裝置）與冷卻系統(tǒng)等重要部件組成。Machine Tool Body床身“Machine Tool Body” is a basic part of the“Machine Tool”. If all these components have been installed in the body, it can guarantee the high accuracy to the whole system because o

21、f the enough rigidity and vibration-resistance. There are two “Hoisting Screws” mounted respectively in the fore-and-aft sides of the “Machine Tools” below DK7750 which have been produced by this Company. They function as hanging the “Machine Tool”. It can remove the “Hoisting Screws” after installa

22、tion. The large-size Machine Tools use the “Hoisting Holes”. The “Supporting Feet”withthe adjustable level have been installed in the bottom of the“Machine Tool Body”. 床身是機床的基礎(chǔ)件。以上這些部件都裝在其上，所以其足夠的剛性與抗振性使整個系統(tǒng)有高精度的保證。本公司生產(chǎn)的DK7750以下機床，其床身前、后兩面各裝有兩個起吊螺絲，其作用是吊裝機床使用。起吊螺絲安裝后可拆下，大型機床用起吊孔，床身底部裝有可供調(diào)節(jié)水平的支承腳。Wo

23、rk-Table工作臺The Worktable is composed of two “Upper and Lower Tool Carriages” making relative cross movements and precise “Lead-Screw Drive Pair”. Please refer to Table 2 and 3 for the “Drive System”.工作臺是由二塊相對十字運動的上下拖板與精密絲杠傳動副所組成，其傳動系統(tǒng)見圖2和圖3。The Structural Formula of “V-Thread Drive” is as follows: (

24、See Table 2)三角螺紋傳動的結(jié)構(gòu)式如下（見圖2）X-Directional: Feed Pulse Step-Motor E1 Gear Pair Z1/Z2 Lead-Screw M1X向：進給脈沖步進電機E1齒輪副Z1/Z2絲杠副M1Y-Directional: Feed Pulse Step-Motor E2 Gear Pair Z3/Z4 Lead-Screw Pair M2Y向：進給脈沖步進電機E2齒輪副Z3/Z4絲杠副M2The Structural Formula of Ball-Screw Drive Pair is as follows: See Table 3滾珠

25、絲杠傳動副的結(jié)構(gòu)式如下，見圖3：X-Directional: Feed Pulse Step-Motor E1 Gear Pair Z1/Z2 Lead-Screw Pair G1X向：進給脈沖步進電機E1齒輪副Z1/Z2絲杠副G1Y-Directional: Feed Pulse Step-Motor E2 Gear Pair Z3/Z4 Lead-Screw Pair G2Y向：進給脈沖步進電機E2齒輪副Z3/Z4絲杠副G2In addition, it can also fulfill the quick movement of the“Work-Table” through “X-Di

26、rectional and Y-Directional Handles”.另外通過X向、Y向兩個手柄，也可實現(xiàn)工作臺快速移動。Page 3第三頁Electrode Wire電極絲Kinetic Wire Tube運絲筒Tacking緊釘Guide Screw B絲桿BWire-Positioning Wheel排絲輪Handle手柄Conductive Wheel導電輪Guide Wheel導輪Diagram 2圖2V-Thread Drive System三角螺紋傳動系統(tǒng)Diagram 3圖3Ball-Screw and Synchronous Belt Drive System滾珠絲杠與同

27、步帶傳動系統(tǒng)Page 4第四頁Kinetic Wire Device運絲裝置It consists of the Motor, Coupler, “Wire Storage Tube”, “Gear Drive Components”, “Slide Plate”, “Kinetic Wire Base”, “Lead-Screw Pair” etc. Because of the action of “Left & Right Link Stoppers” and “Stroke Switch”, it implements the reciprocating movements t

28、o the “Electrode Wire” that has been coiled in “Wire Storage Tube” in order to complete cutting to “Work-Pieces”.由電機、聯(lián)軸器、貯絲筒、齒輪傳動部件、滑板、動絲底座與絲杠副等組成。由于左右撞塊與行程開關(guān)的作用，使纏繞在貯絲筒的電極絲實現(xiàn)往復運動，來完成對工件的切割。Please See Diagram 2 or Diagram 3 for the Drive System:其傳動系統(tǒng)見圖2或圖3：Motor H Coupler High Speed Rotating Wire Tu

29、be Gear Z5/Z6·Z7/Z8 Lead-Screw Pair T電機H聯(lián)軸器高速旋轉(zhuǎn)絲筒齒輪Z5/Z6·Z7/Z8絲杠副T。Coil Holder線架“Coil holder” is a device which supports the “Electrode Wire”, adjusts the “Cutting Thickness” and carries out various“Taper Cutting”. It installs the “Electrode Wire” onto “Work-Piece”which has been chucked in

30、 the “Work-Table” through “Wire-Positioning Wheel”, “Conductive Device”, “Guide-Wheel Group”. “Conductive Block” electrifies “Electrode Wire” under action of “HF Pulse Mains”. The “Liquid Medium” ejected from “Liquid Injection Device” has been broken down to form “Spark Discharge” which completes th

31、e “Work-Piece Cutting”. 線架是用來支承電極絲，調(diào)節(jié)切割厚度與進行各種錐度切割的一個裝置。它通過排絲輪，導電裝置與導輪組，將電極絲引到裝夾于工作臺上的工件上。由于通過導電塊在高頻脈沖電源作用下，使電極絲帶電，利用噴液裝置噴出來的液體介質(zhì)被擊穿后形成火花放電來完成對工件的切割。Because it acts to various “Structural Composition” of the “Coil Holder”, it is divided into “Fixed Coil Holder”, “Adjustable Coil Holder”, “Taper Coil

32、 Holder”.由于作用不同線架的結(jié)構(gòu)形成，通常有固定線架，可調(diào)線架與錐度線架之區(qū)別。Fixed Coil Holder固定線架The “Upper and Lower Coil Holders” of such structural “Coil holder” have been fixed above the “Upright Column”. It can not be adjusted. It has the advantages of the fine Rigidity and sound Machining Stability. But its max. shortcoming

33、lies in the small cutting range whichcan not be regulated. Therefore it has limitations for the product machining. At present, it has been gradually replaced by the “Adjustable Coil Holders”. 此種結(jié)構(gòu)線架其上下懸臂固定于立柱之上，不可調(diào)節(jié)。其優(yōu)點是剛性較好，加工穩(wěn)定性也較好，但其最大缺點是切割圍較小，且不能調(diào)節(jié)，因此產(chǎn)品加工有局限性。目前已逐步被可調(diào)形線架所代替。Elevated Adjustable C

34、oil Holder升降式可調(diào)線架The “upper coil Holder” can move up and down along the“Upright Column” so that it can adapt to the spare machining with different thickness.是使上懸架可沿立柱上下移動，以此來適應(yīng)不同厚度的零件加工。Tapered Type Coil Holder錐度式線架In fact, this Structure is the “Elevated Type” plus one “Taper Cutting Device”. The “

35、Taper Device” produced by our company has the multiple specifications such as 6°, 12°, 15°, 30°, 60° etc. It can basically satisfy various requirements from vast consumers. With the collocation of the corresponding “Control Device”, it can easily fulfill “X, Y, U and V Four-

36、Shaft Linkage”.這種結(jié)構(gòu)實際上是升降式再加上一個錐度切割裝置，本公司生產(chǎn)的錐度裝置有6°、12°、15°、30°、60°等各種規(guī)格，基本上能滿足用戶的各種需要，配上相應(yīng)的控制裝置能很容易地實現(xiàn)X、Y、U和V四軸聯(lián)動。Technical Parameters技術(shù)參數(shù)Characteristic Model Stipulations特性型號的規(guī)定At present, DK77 serial goods produced by our company is mainly divided into three kinds of Mode

37、l E, Model F, Model G according to different“Power Stroke” (Specification) and Structural Form of the Coil Holder. 我公司目前生產(chǎn)的DK77系列產(chǎn)品，主要是按其工作行程（規(guī)格）與其線架結(jié)構(gòu)形式不同可分為E型、F型和G型三種。Model E Adjustable Coil Holder Height, therefore it is called “Adjustable Coil Holder”.E型線架高度可調(diào)節(jié)，稱可調(diào)線架。Model F The “Coil Holder Hei

38、ght” can be regulated, it is also allocated with below 6° Taper Cutting Device. Therefore it is called “Adjustable Small-Taper Coil Holder”.F型線架高度可調(diào)節(jié)且配以6°以下錐度切割裝置，稱可調(diào)小錐度線架。Model G The“Coil Holder Height” can be regulated. It is also allocated with our patent “Large-Taper Cutting Device”wit

39、h the “Tracking Hydrojet”. It is called “Large Taper Coil Holder”. It commonly has 30° or 60° Upper Limit Specifications and so on.G型線架高度可調(diào)節(jié)且配以由公司專利的帶跟蹤噴液的大錐度切割裝置。大錐度線架，常用的有上限為30°或60°等各種規(guī)格。The Model Composition and Representative Meaning are in line with Standards /T7445 and 2-94

40、.型號組成與代表意義依據(jù)標準/T7445、2-94。Coil Holder Form線架形式Principal Parameter (Work-Table Lateral Stroke 1/10)主參數(shù)（工作臺橫向行程1/10）Machine Tool Series機床系列National Machine Tool No.機床組別Machine Tool Properties機床特性Machine Tool Category機床類別Page 5第5頁Technical Parameters技術(shù)參數(shù)Unit: mm單位：mmModel型號Parameter參數(shù)Power Stroke工作行程Ma

41、x. Length of Machining Part加工件最大長度Max. Width of Machining Part加工件最大寬度Machining Part Thickness加工件厚度Cutting Taper切割錐度Model FF型Model GG型Max. Weight of Machining Part加工件最大重量Work-Piece Surface Roughness工件表面粗糙度Max. Material Removal Ratio最大材料去除率Current Range of Electrode Wire電極絲電流圍Operating Mains工作電源Max. M

42、achining Current最大加工電流Control Mode控制方式Control Accuracy控制精度Total Weight of Machine Tool機床總重量Outer Diameter Size of Machine Tool機床外徑尺寸Open-Loop, Step-Motor Drive開環(huán)、步進電機驅(qū)動Description:說明：The above “Cutting Taper” and “Operating Thickness” take 150mm as the “Calculation Height”.以上切割錐度、工作厚度以150mm為計算高度；Sur

43、face Roughness Ra2.5m has been determined when “Cutting Speed” is 20mm2/min.表面粗度Ra2.5m，是在切割速度為20mm2/min.時測定的。Page 6第6頁Machine tool handling and installation機床的搬運和安裝Machine Tool Handling and Hoisting 機床的搬運和吊裝Machine tool handling can be hoisted or use the lift-truck. Please refer to diagram 4 for out

44、er packing box hoisting. If there is no packing box, please refer to diagram 5 with the utilization of double ends of machine tool body and four hoisting screws for lift. Please be noted that the hoisting screw should be tightly wrenched and the face tightly stuck to the body. Otherwise it easily br

45、eaks the screw root and causes the unnecessary accidents. As for the large-size machine tool above Dk7763, it should use theenough intensity hoisting bar. Soft materials should be filled between the wire rope and machine tool contact so that it will not damage the outer appearance. Un-smooth circums

46、tances such as jolt, tilt, impact etc. should be avoided in the handling. 機床的搬運可用吊裝，也可用鏟車。當有外包裝箱吊運時可見圖4，若無包裝箱則可利用床身兩端，四只起吊螺絲起吊，見圖5。注意起吊螺絲必須擰緊，其端面必須緊貼床身，否則螺絲根部容易折斷，造成不必要的事故。對于Dk7763以上的大型機床，必須用具有足夠強度的起吊棒。鋼絲繩與機床接觸處要填放軟性物質(zhì)，以免損傷外觀。搬運中應(yīng)避免顛簸、傾斜、撞擊等不平穩(wěn)現(xiàn)象。Machine Tool Installation機床安裝It should keep a clean,

47、dust-free installation environment without vibrating source; corrosive gas and large wattage electrical equipment interference. It better controls 20±5 to the operating environment temperature. 安裝環(huán)境應(yīng)清潔，無粉塵、無振動源，無腐蝕氣體，無大功率電氣設(shè)備干擾。建議工作環(huán)境溫度最好控制在20±5。As far as the “Installation Direction of the

48、 Machine Tool” is concerned, it is better for the operator to face the“Natural Light Source”. After the initial placement of the Machine Tool, firstly remove the “Locking Blocks” on both ends of the“Guide Rail” and replace them with the Machine Backups, then wash the key “Drive Members” such as “Lea

49、d-Screw Pair”, “Guide Rail”, “Guide Wheel” etc. by the clean kerosene and immediately coat with clean HJ-30 Lubricant in order to prevent from rusting. Relying on the adjustable Screws below the “Machine Tool Body”, it should not exceed 0.04/1000 requirements for the lateral and longitudinal directi

50、ons of the“Level Gauge” in the “Work-Table”. The Machine Tool should have the reliable connection withthe“Protective Ground System” for purpose of ensuring the safe use. 機床安裝方向盡量使操作者面對自然光源。機床初步安放后，應(yīng)拆去導軌兩端鎖緊塊，換上隨機帶的擋塊，然后用干凈煤油清洗絲杠副、導軌、導輪等重要傳動件，要立即擦上清潔的HJ-30機油以防生銹。借助床身下面的調(diào)整螺釘，使水平儀在工作臺縱橫二個方向均不得超過0.04/10

51、00的要求。機床應(yīng)與保護接地裝置可靠連接，以確保使用安全。Diagram 4圖4Hoisting Diagram of Outer Packing Lifting Box外包裝吊箱吊運圖Page 7第7頁Machine Tool Adjustment and Operation 機床調(diào)整與操作Preparation Works準備工作On-Line聯(lián)機Please carefully read “Use Description of Two Parts of Machinery & Machine Tool Running System” before on-line in order

52、 to correctly connect the Sockets with various Plugs.聯(lián)機前應(yīng)仔細閱讀機械與電器二部分使用說明書，使其各個插頭與插座，得以正確的聯(lián)接。Start the “Mains Switch”, make No-Load Running of the Machine Tool, observe whether it has the normal working condition or not.啟動電源開關(guān)，讓機床空載運行，觀察其工作狀態(tài)是否正常。The contents include the following:容有：The “Control Ca

53、binet” should have more than ten minutes normal operation.控制柜必須正常工作十分鐘以上；It should have the normal operation for various parts of the “Motion Pair” in the Machine Tool.機床各部分運動副工作正常；No Error in “Pulse Mains” and “Machine Tool Running System Operation”脈沖電源與機床電器工作無失誤；It should have sensitive action of

54、various “Stroke Switch Contacts”.各個行程開關(guān)觸點動作靈敏；Smooth flow of the “Working Solution” in various “Inlet and Outlet Pipes” with normal pressure, the “Working Solution” should wrap “Molybdenum Wire”. 工作液各進出管暢通無阻，壓力正常，工作液裹住鉬絲。Fill the Lubricant according to the lubricating demands of theMachine Tool.按機床潤

55、滑要求注油；See Diagram 6, Diagram 7 and Table 2.見圖6、圖7和表2Please accord with table 2 stipulations for Machine Tool Lubrication with regular oil adding. Because it is a high speed Wire-Traveling Machine Tool, therefore whether various systems have normal lubrication or not is vital to the Cutting Accuracy and Roughness. The consumers should think high of this very point.機床潤滑請按表2規(guī)定，定期加油，由于本機床為高速走絲，所以各系統(tǒng)的潤滑是否正常，對其切割精度與粗糙度是至關(guān)重要，因此務(wù)必請用戶重視。Diagram 5圖5Machine Tool Main Frame