中英文DK77系列数控电火花线切割机床使用说明书

中英文DK77系列数控电火花线切割机床使用说明书 封面: DK77 Series NC EDM Wire-Cutting Machine Tool DK77系列数控电火花线切割机床 Use Description 使用说明书 Ningbo Zhongyuan Machine Tool Co., Ltd. 宁波中原机床有限公司 Catalogue 目录 Machine Tool Use 机床用途 Machine Tool Features 机床特点 Main Use 主要用途 Structure and Principle of Operation 工作原理及结构 Principle of Operation 工作原理 Mechanical System Structure 机械系统结构 Technical Parameters 技术参数 Characteristic Model Stipulations 特性型号的规定 Basic Parameters 基本参数 Machine Tool Handling and Installation 机床的搬运与安装 Machine Tool Handling and Hoisting 1 机床的搬运与吊装 Machine Tool Installation 机床的安装 Machine Tool Adjustment and Operation 机床调整与操作 Preparation Works 准备工作 Coil Holder Adjustment 线架调整 Worktable Regulation 工作台调整 Kinetic Wire Component Adjustment and Electrode Wire Coiling 运丝部件调整及电极丝绕装 Guide Wheel Adjustment 导轮的调整 Work-Piece Clamping 工件装夹 Operation and Points for Attention 操作及注意事项 Machine Tool Maintenance and Trouble Removal 机床的维护与故障的排除 Machine Tool Maintenance 机床的维护 Common Troubles and Removals of the Machine Tool 机床的常见故障与排除 Vulnerable Part Table 易损零件 表 关于同志近三年现实表现材料材料类招标技术评分表图表与交易pdf视力表打印pdf用图表说话 pdf Machine Tool Running System Installation and Use Description 机床电器安装及使用说明 2 Summary of Machine Tool Running System and Control System 电器控制系统概述 Common Troubles of Machine Tool Running System: Causes and Removals 电器常见故障:原因及排除 Safety Protection Measures of Machine Tool Running System 机床电器安全保护措施 Schematic Drawing of 25V Drive Head Mains 25伏驱头电源原理图 Schematic Drawing of Machine Tool Running System 机床电器原理图 DK77 Series DK77系列 Use Description of Machine Tool 机床使用说明书 38 Pages Total 共38页 Page 1 第一页 Machine Tool Use 机床用途 Machine Tool Features 机床特点 Max. feature of this serial product 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-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 the special spares which terrify other Machine Tools. Following the constant 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. 本系列产品最大特点是对被加工的金属材料性质无特殊要求，原则上凡导电材料均可加工。 3 如超硬、硬质合金、淬火材料;如不锈钢类的韧性材料;各类磁钢的脆性材料;不易装夹的 薄壁零件。若机床辅以本公司制造的特大规格锥度切割装置与响应微机系统，那么对其他机 床望而生畏的各种特异零件加工都能取得令人满意的效果。随着高科技产品不断出现，国民 经济的不断繁荣，我们预言，本系列产品的特点将进一步得到开发利用，受到各位客户的欢 迎。 Main Use 主要用途 It processes various molds such as rubber and plastic molds, punch die and so on. 加工各类模具:橡塑模、冲模等等。 It processes the special materials of fragile materials, stainless steel ductile materials, super-hard materials. 加工特殊材料:脆性材料、不锈钢韧性材料、超硬材料。 It processes the complex-shape spares such as the tapered upper and lower specially-shaped spares and so forth. 加工复杂形状零件:带锥度的上下异形零件等。 Structure and Principle of Operation 工作原理及结构 Principle 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 Control with Micro-Computers. The Machine Tool usually adopts “Molybdenum Wire” or “Hard Brass Wire” as the “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 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. 本系列产品是应用“放电加工”机理，辅以自动控制及微机相结合的机电一体化产品。机床 通常采用钼丝或硬性黄铜丝作为工具电极，在高频脉冲电压作用下，利用液体介质被击穿后 形成火花放电，在火花通道中瞬间产生大量的热能，使工件表面的金属熔化甚至气化，加上 液体介质的共同作用，而使金属被迅速蚀除下来。装夹于座标工作台上的工件在微机控制下 按预行编制的程序被加工出各种所需的形状。 Please Refer to Diagram 1 for its Basic Composition 其基本组成见图1 4 File 文件 Programming 编程 Reader 输入机 Power Amplification 功放 Micro-Computer 微机 Variable Frequency 变频 Detection 检测 Calculation System 运算系统 Step-Motor 步进电机 Machine Tool 机床 Pulse Mains 脉冲电源 Diagram 1 图1 Machine Tool Composition Diagram 机床组成方框图 Page 2 第二页 We can see from the above diagram that the whole system is composed of the “Computer System”, 5 “Machine Tool Control System”, “Mechanical System”. 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 includes the “Coordinates Work-Table”, “Kinetic Wire System”, “Cooling System”. 由上图可见整个系统主要由计算机系统、机床控制系统和机械系统组成。加工文件通过编程 形成计算机输入机床控制系统，并由控制系统控制机床完成程序的动作，以此完成加工指令。 机械系统以床身为基础，包括坐标工作台、运丝系统、冷却系统。 The “Micro-Computer System” allocated by this Machine Tool is a new generation “Control System”. For details, please 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 advanced CNC technology. 本机所配的微机系统是新一代的控制系统，详见〈使用说明书、电器部分〉。其主要由微机 配上专用的插补控制软件及接口电路和步进驱动电路组成，由于采用了先进的CNC技术， 所以具有良好的操作性。 Mechanical System Structure 机械系统结构 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 Holder” (including Taper Device), “Cooling System” etc. 本机床的机械系统部分由床身、工作台、运丝装置、线架(包括锥度装置)及冷却系统等重 要部件组成。 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 of 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 installation. The large-size Machine Tools use the “Hoisting Holes”. The “Supporting Feet” with the adjustable level have been installed in the bottom of the “Machine Tool Body”. 床身是机床的基础件。以上这些部件都装在其上，所以其足够的刚性与抗振性使整个系统有 高精度的保证。本公司生产的DK7750以下机床，其床身前、后两面各装有两个起吊螺丝， 其作用是吊装机床使用。起吊螺丝安装后可拆下，大型机床用起吊孔，床身底部装有可供调 节水平的支承脚。 Work-Table 6 工作台 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”. 工作台是由二块相对十字运动的上下拖板及精密丝杠传动副所组成，其传动系统见图2和图3。 The Structural Formula of “V-Thread Drive” is as follows: (See Table 2) 三角螺纹传动的结构式如下(见图2) X-Directional: Feed Pulse ? Step-Motor E? Gear Pair Z/Z? Lead-Screw M 1121X向:进给脉冲?步进电机E?齿轮副Z/Z?丝杠副M 1121 Y-Directional: Feed Pulse ? Step-Motor E? Gear Pair Z/Z? Lead-Screw Pair M2342 Y向:进给脉冲?步进电机E?齿轮副Z/Z?丝杠副M2342 The Structural Formula of Ball-Screw Drive Pair is as follows: See Table 3 滚珠丝杠传动副的结构式如下，见图3: X-Directional: Feed Pulse ? Step-Motor E? Gear Pair Z/Z? Lead-Screw Pair G112 1 X向:进给脉冲?步进电机E?齿轮副Z/Z?丝杠副G1121 Y-Directional: Feed Pulse ? Step-Motor E? Gear Pair Z/Z? Lead-Screw Pair G2342 Y向:进给脉冲?步进电机E?齿轮副Z/Z?丝杠副G2342 In addition, it can also fulfill the quick movement of the “Work-Table” through “X-Directional and Y-Directional Handles”. 另外通过X向、Y向两个手柄，也可实现工作台快速移动。 Page 3 第三页 Electrode Wire 电极丝 Kinetic Wire Tube 运丝筒 Tacking 紧钉 Guide Screw B 丝杆B 7 Wire-Positioning Wheel 排丝轮 Handle 手柄 Conductive Wheel 导电轮 Guide Wheel 导轮 Diagram 2 图2 V-Thread Drive System 三角螺纹传动系统 Diagram 3 图3 Ball-Screw and Synchronous Belt Drive System 滚珠丝杠及同步带传动系统 Page 4 第四页 Kinetic Wire Device 运丝装置 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 to the “Electrode Wire” that has been coiled in “Wire Storage Tube” in order to complete cutting to “Work-Pieces”. 由电机、联轴器、贮丝筒、齿轮传动部件、滑板、动丝底座及丝杠副等组成。由于左右撞块及行程开关的作用，使缠绕在贮丝筒的电极丝实现往复运动，来完成对工件的切割。 Please See Diagram 2 or Diagram 3 for the Drive System: 其传动系统见图2或图3: Motor H? Coupler ? High Speed Rotating Wire Tube ? Gear Z/Z?Z/Z? Lead-Screw 5678 Pair T 电机H?联轴器?高速旋转丝筒?齿轮Z/Z?Z/Z?丝杠副T。 5678 8 Coil Holder 线架 “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 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 the “Work-Piece Cutting”. 线架是用来支承电极丝，调节切割厚度及进行各种锥度切割的一个装置。它通过排丝轮，导 电装置及导轮组，将电极丝引到装夹于工作台上的工件上。由于通过导电块在高频脉冲电源 作用下，使电极丝带电，利用喷液装置喷出来的液体介质被击穿后形成火花放电来完成对工 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 Holder”. 由于作用不同线架的结构形成，通常有固定线架，可调线架及锥度线架之区别。 Fixed Coil Holder 固定线架 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 lies in the small cutting range which can not be regulated. Therefore it has limitations for the product machining. At present, it has been gradually replaced by the “Adjustable Coil Holders”. 此种结构线架其上下悬臂固定于立柱之上，不可调节。其优点是刚性较好，加工稳定性也较 好，但其最大缺点是切割范围较小，且不能调节，因此产品加工有局限性。目前已逐步被可 调形线架所代替。 Elevated Adjustable Coil Holder 升降式可调线架 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. 是使上悬架可沿立柱上下移动，以此来适应不同厚度的零件加工。 Tapered Type Coil Holder 锥度式线架 In fact, this Structure is the “Elevated Type” plus one “Taper Cutting Device”. The “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 9 collocation of the corresponding “Control Device”, it can easily fulfill “X, Y, U and V Four-Shaft Linkage”. 这种结构实际上是升降式再加上一个锥度切割装置，本公司生产的锥度装置有6?、12?、 15?、30?、60?等各种规格，基本上能满足用户的各种需要，配上相应的控制装置能很容 易地实现X、Y、U和V四轴联动。 Technical Parameters 技术参数 Characteristic Model Stipulations 特性型号的规定 At present, DK77 serial goods produced by our company is mainly divided into three kinds of Model E, Model F, Model G according to different “Power Stroke” (Specification) and Structural Form of the Coil Holder. 我公司目前生产的DK77系列产品，主要是按其工作行程(规格)及其线架结构形式不同可 分为E型、F型和G型三种。 Model E — Adjustable Coil Holder Height, therefore it is called “Adjustable Coil Holder”. E型——线架高度可调节，称可调线架。 Model F —— The “Coil Holder Height” can be regulated, it is also allocated with below 6? Taper Cutting Device. Therefore it is called “Adjustable Small-Taper Coil Holder”. F型——线架高度可调节且配以6?以下锥度切割装置，称可调小锥度线架。 Model G —— The “Coil Holder Height” can be regulated. It is also allocated with our patent “Large-Taper Cutting Device” with the “Tracking Hydrojet”. It is called “Large Taper Coil Holder”. It commonly has 30? or 60? Upper Limit Specifications and so on. G型——线架高度可调节且配以由公司专利的带跟踪喷液的大锥度切割装置。大锥度线架， 常用的有上限为30?或60?等各种规格。 The Model Composition and Representative Meaning are in line with Standards JB/T7445 and 2-94. 型号组成及代表意义依据 标准 excel标准偏差excel标准偏差函数exl标准差函数国标检验抽样标准表免费下载红头文件格式标准下载 JB/T7445、2-94。 Coil Holder Form 线架形式 Principal Parameter (Work-Table Lateral Stroke 1/10) 主参数(工作台横向行程1/10) Machine Tool Series 机床系列 10 National Machine Tool No. 机床组别 Machine Tool Properties 机床特性 Machine Tool Category 机床类别 Page 5 第5页 Technical Parameters 技术参数 Unit: mm 单位:mm Model 型号 Parameter 参数 Power Stroke 工作行程 Max. Length of Machining Part 加工件最大长度 Max. Width of Machining Part 加工件最大宽度 Machining Part Thickness 加工件厚度 Cutting Taper 切割锥度 Model F F型 Model G G型 11 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 电极丝电流范围 Operating Mains 工作电源 Max. Machining Current 最大加工电流 Control Mode 控制方式 Control Accuracy 控制精度 Total Weight of Machine Tool 机床总重量 Outer Diameter Size of Machine Tool 机床外径尺寸 Open-Loop, Step-Motor Drive 开环、步进电机驱动 Description: 说明: The above “Cutting Taper” and “Operating Thickness” take 150mm as the “Calculation Height”. 以上切割锥度、工作厚度以150mm为计算高度; 2Surface Roughness Ra?2.5m has been determined when “Cutting Speed” is 20mm/min. 2表面粗度Ra?2.5m，是在切割速度为20mm/min.时测定的。 Page 6 12 第6页 Machine tool handling and installation 机床的搬运和安装 Machine Tool Handling and Hoisting 机床的搬运和吊装 Machine tool handling can be hoisted or use the lift-truck. Please refer to diagram 4 for outer 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 breaks the screw root and causes the unnecessary accidents. As for the large-size machine tool above Dk7763, it should use the enough 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 circumstances such as jolt, tilt, impact etc. should be avoided in the handling. 机床的搬运可用吊装，也可用铲车。当有外包装箱吊运时可见图4，若无包装箱则可利用床 身两端，四只起吊螺丝起吊，见图5。注意起吊螺丝必须拧紧，其端面必须紧贴床身，否则 螺丝根部容易折断，造成不必要的事故。对于Dk7763以上的大型机床，必须用具有足够强 度的起吊棒。钢丝绳与机床接触处要填放软性物质，以免损伤外观。搬运中应避免颠簸、倾 斜、撞击等不平稳现象。 Machine Tool Installation 机床安装 It should keep a clean, 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. 安装环境应清洁，无粉尘、无振动源，无腐蚀气体，无大功率电气设备干扰。建议工作环境 温度最好控制在20?5?。 As far as the “Installation Direction of the 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 “Lead-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 directions of the “Level Gauge” in the “Work-Table”. The Machine Tool should have the reliable connection with the “Protective Ground System” for purpose of ensuring the safe use. 机床安装方向尽量使操作者面对自然光源。机床初步安放后，应拆去导轨两端锁紧块，换上 随机带的挡块，然后用干净煤油清洗丝杠副、导轨、导轮等重要传动件，要立即擦上清洁的 HJ-30机油以防生锈。借助床身下面的调整螺钉，使水平仪在工作台纵横二个方向均不得超 13 过0.04/1000的要求。机床应与保护接地装置可靠连接，以确保使用安全。 Diagram 4 图4 Hoisting Diagram of Outer Packing Lifting Box 外包装吊箱吊运图 Page 7 第7页 Machine Tool Adjustment and Operation 机床调整与操作 Preparation Works 准备工作 On-Line 联机 Please carefully read “Use Description of Two Parts of Machinery & Machine Tool Running System” before on-line in order to correctly connect the Sockets with various Plugs. 联机前应仔细阅读机械与电器二部分使用说明书，使其各个插头与插座，得以正确的联接。 Start the “Mains Switch”, make No-Load Running of the Machine Tool, observe whether it has the normal working condition or not. 启动电源开关，让机床空载运行，观察其工作状态是否正常。 The contents include the following: 内容有: The “Control Cabinet” should have more than ten minutes’ normal operation. 控制柜必须正常工作十分钟以上; It should have the normal operation for various parts of the “Motion Pair” in the Machine Tool. 机床各部分运动副工作正常; No Error in “Pulse Mains” and “Machine Tool Running System Operation” 脉冲电源与机床电器工作无失误; It should have sensitive action of various “Stroke Switch Contacts”. 各个行程开关触点动作灵敏; Smooth flow of the “Working Solution” in various “Inlet and Outlet Pipes” with normal pressure, 14 the “Working Solution” should wrap “Molybdenum Wire”. 工作液各进出管畅通无阻，压力正常，工作液裹住钼丝。 Fill the Lubricant according to the lubricating demands of the Machine Tool. 按机床润滑要求注油; See Diagram 6, Diagram 7 and Table 2. 见图6、图7和表2 Please 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. 机床润滑请按表2规定，定期加油，由于本机床为高速走丝，所以各系统的润滑是否正常，对其切割精度与粗糙度是至关重要，因此务必请用户重视。 Diagram 5 图5 Machine Tool Main Frame Hoisting Diagram 机床主机吊运图 Page 8 第8页 K-Directional K向 Diagram 6 图6 The Conceptual Diagram to various “Kinetic Part Lubricating Positions” of the Work-Table 工作台各运动件润滑部件示意图 Diagram 7 图7 Lubricant Oil of “Kinetic Wire Component” 运丝部件润滑油 Table 2 表2 No. Lubricating Lubricating Oil Adding Points for Attention 15 编号 Positions Mode 油类 Time 注意事项 润滑部位 润滑方式 加油期 Table Lead-Screw Oil Gun 30# Once a During the oil adding time, 6 丝杠 油枪 Lubricant Week please shake the “Hand 图6 30#机油 每周一次 Wheel” at the same time so A、B that the Lead-Screw can make the round-trip movements. 加油时必须同时摇动手轮 使丝杠全程运动 Table Guide Rail Oil Gun 30# Once a During the oil adding time, 6 导轨 油枪 Lubricant Week please shake the hand wheel 图6 30#机油 每周一次 at the same time so that the C、guide rail can make the D、round-trip movements. E、F 加油时必须同时摇动手轮 导轨全程运动 Work-table gear Oil gun 30# Once a During the oil adding time, 工作台齿轮 油枪 lubricant week please shake the hand wheel 30#机油 每周一次 at the same time so that the gear can rotate for several cycles. 加油时必须同时摇动手轮 使齿轮转几圈 Table Bearing Pressure 2# calcium Once half a Before oil change, please 7 轴承 oil gun lubricating year clean the Bearing and Base. 图7 压力油枪 grease 半年一次 换油前，将轴承及座清洗干 A、C 2#钙基润净 滑脂 Table Guide Rail Oil Gun 30# Once a During oil adding period, 7 导轨 油枪 Lubricant Week please let the “Tool 图7 30#机油 每周一次 Carriage” make the F、 round-trip movements. B、G 加油时，使拖板全行程移动 Table Gear Oil Gun 30# Once a 7 齿轮 油枪 Lubricant Week 图7 30#机油 每周一次 D Table Gear Mounted Oil Gun 30# Once a 16 7 Shaft 油枪 Lubricant Week 图7 齿轮安装轴 30#机油 每周一次 E Table Lead-Screw Pair Oil Gun 30# Once a 7 丝杠副 油枪 Lubricant Week 图7 30#机油 每周一次 H Wire-Positioning Pressure 2# Calcium Once Half During the oil change, please Wheel Bearing Oil Gun Lubricating a Month clean the “Guide Wheel 排丝轮轴承 压力油枪 Grease 半月一次 Base. 2#钙基润换油时，将导轮座清洗干 滑脂 净。 Add and change the “Working Solution” 添加和更换工作液 It is proper to change the working solution every seven to ten days. 一般以每7,10天更换一次为宜。 Coil holder adjustment 线架调整 Height regulation 高度调整 Please refer to table 2 or table 3 见图2或图3 Loosen the platen screw at the side and in the rear part of the coil holder, then rotate the elevation lead-screw to adjust the height of the upper coil holder in order to adapt to various thickness of the machining parts, finally tightly wrench the platen screw and positioning screw at the side and in the rear part. 拧松上悬臂侧面与后面的压板螺丝，然后转动升降丝杠来调节上悬臂的高度，以适应加工零 件的不同厚度，最后再拧紧侧面与后面的压板螺丝与定位螺丝。 Verticality regulation between electrode wire and the work-piece 电极丝与工件的垂直度调整 It can use the “Precision Right-Angle” or “Model DF55-J50A Electrode Wire Verticality Corrector” (Please refer to “Use Description of Corrector” for the use methods) to correct the none verticality between “Electrode Wire” and “Work-Piece”. Firstly loosen the “Holding Screw” of two “Guide Wheels” in the front end of the “Coil Holder”, then slightly adjust the left and right positions of the “Guide Wheel” in order to fulfill the “Electrode Wire Verticality”. This method 17 is only fit for “E type Vertical Wire Holder”. 可用精密直角或DF55-J50A型电极丝垂直校正器(使用方法见校正器的使用说明书)来纠正电极丝与工件的不垂直。可先拧松悬臂前端二只导轮的紧定螺钉，再微量调节导轮左、右位置，以达到电极丝的垂直度，这种方法仅仅适用E型直升丝架。 As to the “Wire Holder” mounted with “F type or G type Taper Head”, or with the Taper Head, it is more easy to regulate the verticality of the “Electrode Wire”. Only the slight adjustment of “U Shaft” and “V Shaft” positions can fulfill the verticality requirements. 对于装有F型或G型锥度头的丝架，锥度头的丝架，其电极丝的垂直度调整就容易多了。只要稍微调整U轴和V轴的位置，即能实现垂直要求。 第10页 Taper Cutting Adjustment 锥度切割的调整 Taking a small “Taper Head” produced by this Company as an example, it describes the importance of reasonably choosing the relevant parameters. The “Small Taper Head Principle” can be simplified into what is shown in Table 8: 以本公司一小锥度头为例来说明合理选用有关参数重要性。小锥度头原理可简化成图8所示: Therefore it get the following “Relational Expression”: 由此可得下列关系式 Among which A is oblique angle = taper angle / 2 式中a为斜角=锥角/2 U and V are U-directional and V-directional moving volume of the “Upper Guide Wheel”. H is the central distance between “Upper and Lower Guide Wheels”. U和V为上导轮的U向和V向的移动量，H为上下导轮的中心距 It draws the conclusion from the above “Relational Expression” that 由上式可见: U?(or V?), then a?, otherwise it results in a? U?(或V?)则a?，反之则a? H? then a?, otherwise it results in a? H?则a?，反之则a? Therefore in the same specification of the taper heads, only the reasonably regulation of U (or V) and H numeric values can get the ideal cutting effects. 所以在同一规格的锥度头上，只要合理调整U(或V)和H的数值，就能得到理想的切割效果。 18 It has already calculated the upper limit value of U and V two parameters in design. At present, we take the following example: When our commonly-used U (or V) taper head whose moving volume is 30mm, what is the proper central distance H adjustment between upper and lower guide wheels while processing the work-piece with 12? taper and 120mm thickness? U和V这二个参数的上限值在设计时已计算好。现举本公司一常用U(或V)的移动位置 为30mm的锥度头为例，来核算一下要加工锥度为12?，厚度为120mm的工件其上下导轮 中心距H调整到多少为合适, It draws the conclusion from the formula (1): 由公式(1)可知 Therefore as long as central distance H?142.72mm, it can process the work-pieces with 12? taper. If H?142.72mm, then it can not process 12? taper. As material thickness 120mm falls into its range, so it allows the processing. 由此可见只要中心距H?142.72mm就能加工出12?锥度的工件，若H?142.72mm，则12? 的锥度就加工不出来了。因材料厚度120mm在其范围内，因此是允许加工的。 Work-table regulation 工作台调整 The work-table had been driven by step-motor. It completes X and Y directional movements through the gear stand and lead-screw pair. The transmission of the large specification of this series adopts the high precision non-clearance ball lead-screw pair. Their clearances have been regulated when they leave the factory. Therefore it is not necessary for the customers to make regulation by their own. The small specification products utilize the high accuracy slide lead-screw pair. Their clearances have been fulfilled through adjusting one auxiliary nut in the combined nuts. Please refer to diagram 9: 工作台是由步进电机来驱动，通过齿轮架及丝杠副来完成X、Y两个方向的运动。本系列的 大规格产品其传动采用高精度无间隙的滚珠丝杠副，它们的间隙出厂时都已调整好，客户不 必自行调整。小规格的产品采用高精度滑动丝杠副，它们的间隙是通过调整组合螺母内的一 只副螺母来实现的，见图9。 u or v u或v Upper guide wheel 上导轮 Work-piece 工件 Tool 工具 19 Upper table 上台面 Lower guide wheel 下导轮 Diagram 8 图8 Page 11 第11页 Diagram 9 图9 Lead-screw clearance regulation methods: 丝杠间隙调整法 The ex-factory lead-screw clearance has been elaborately adjusted during the assembly process. It has been operated under the best conditions. Through a period of use, the nut will possibly have the slight wear. Therefore the gas of lead-screw pair will be enlarged. It needs the self-regulation from the consumers too. 出厂时的丝杠副的间隙在装配时已通过精心调整，都在最佳状态下工作，经过一个阶段使用， 螺母可能为出现微量磨损，因此丝杠副的间隙会增大，这时用户可以自行调整: Check whether the Nut has been tightly fixed into “Nut Base Combination Face B” or not. Retention Screw 5. 检查螺母与螺母座结合面B应贴紧，紧固螺钉5。 Press “ENGAGE” key in the control keyboard, shake the work-table hand wheel to check whether the step-motor has been engaged or not. Hold the scale disk by hand and wring it slightly, examine that if there is any left or right loosening of scale value with comparison to “0” level of graduation mark. The lead-screw pair clearance should be regulated for any loosening. (See table 9) The adjusting methods are as follows: 按下控制键盘的电极吸键，摇动工作台手轮检查步进电机是否吸住，手握刻度盘并轻轻拧动， 检查刻度值相对“0”位刻线有无左右松动，若有松动就应调整丝杠副间隙(见图9)调整 方法如下: Firstly loosen two hexagon socket screws 6, then rotate clockwise the auxiliary nut 2 to reduce clearance between lead-screw and the whole combined nut. (Anticlockwise rotation is for clearance increase) Then tightly screw in two bolts 6, it is forbidden to touch bolt 5 during the clearance adjustment. 先松开两内六角螺钉6然后顺时针转动付螺母2，使整个组合螺母与丝杠的间隙减少(逆时 20 针转动则增大间隙)然后再拧紧两个螺钉6，调整间隙时不许动螺钉5。 Kinetic Wire Component Regulation and Electrode Wire Coiling 运丝部件调整及电极丝绕装 Left and Right Link Stopper Adjustment (See Table 10) 左右撞块的调整(见图10) Properly adjust the positions of the left and right “Link Stoppers” according to the “Coiled Electrode Wire Length” so that it can just touch the “Stroke Switch” in order to fulfill the reciprocating movements of the “Wire Storage Tube”. 根据缠绕好的电极丝长度，适当调节好左右二撞块的位置，使其刚好能触及行程开关，实现 贮丝筒的往复运动。 Clearance Adjustment of Driving Lead-Screw Pair 传动丝杠副的间隙调整 Right Link Stopper 右撞块 Left Link Stopper 左撞块 Stroke Switch 行程开关 Table 10 图10 Conceptual Diagram of Wire Storage Tube Left and Right Link Stoppers 贮丝筒左、右撞块示意图 第12页 Because the high rotating speed “Wire Tube” transfers the same high rotation rate to the “Lead-Screw” with frequent commutating, therefore its “Lead-Screw Pair Wear” is much larger than that of the “Worktable Lead-Screw Pair”. For this reason, it should timely well-adjust the clearance in order to keep its high kinetic accuracy. Its adjusting methods are the same as the “Work-Table Lead-Screw Pair Regulation”. Here we make no mention of it any more. 由于高转速的丝筒传递给丝杠的转速也很高，且换向频繁，所以其丝杠副的磨损远大于工作 台的丝杠副。因此要及时调节好间隙，使其保持较高的运动精度，其调节方法与工作台丝杠 副调节相同，此处略去不谈。 Adjustment of the Guide Rail Clearance 导轨间隙的调节 21 Because of some unfavorable factor influences in the motion, though a period time of running, the “Electrode Wire” is loosened or tightened in single side of the “Wire Tube”, it is very harmful to the cutting. And it seriously influence the cutting precision too. Therefore it should properly adjust the bolts 2 in the “Guide Rail Regulative Plate 1” in order to increase the running accuracy. It can improve the single side loosening or tightening as well. (See Diagram 11) 由于运动中的某些不利因素影响，经过一段时间的运行，使电极丝在丝筒上出现单边松紧现 象，这是切割中的大忌，它严重影响切割精度，此时若能适当调整导轨调节板1上几个螺钉 2，以提高运行精度，就能改善单边松紧现象。(见图11) Electrode Wire Coiling 电极丝绕装 Respectively move the left and right “Link Stoppers” to both ends before machine-start. 开机前将左右撞块各移向两端。 Machine-operate or manual-operate the end position of “Wire Tube” near “Coil Holder Guide-Wheel Center” 机动或手动将丝筒终端位置走至悬臂导轮中心附近 Coil the “Electrode Wire” into a proper “Core Rod”, one end of the “Electrode Wire” goes from “Wire-Positioning Wheel” to “Wire Tube”, it has then been pressed by bolt. After evenly coil the wire for several circles, swing the “Wire Tube Handle” by one hand (it can also be machine-operated), hold the “Core Rod” by another hand, put certain “Drag Force” onto “Electrode Wire Disk”, coil the “Electrode Wire” onto another end of the “Wire Tube”, then stop the Machine Tool and cut off the “Electrode Wire” according to the needed “Wire Mounting Volume”, then put the “Electrode Wire” onto “Guide Wheel”, “Conductive Block”, “Guide-Wheel Water-Jet Nozzle” etc., then the “Electrode Wire” goes down to “Lower Coil Holder Wire-Positioning Rod”, it returns to “Wire Tube” and has been tightly pressed into it. Depending on the proficiency degree of operation, it also has other “Wire-Mounting Methods”. We hereby do not go into details any more. 取电极丝盘串于一合适的芯棒上将电极丝一端串过排丝轮后缠绕到丝筒上用螺钉压住，均匀 缠绕几圈后，然后一手摇动丝筒手柄(也可以机动)一手拿住芯棒，并施于一定阻力于电极 丝盘上，将电极丝绕至丝筒另一端，根据需要的上丝量，停机剪断电极丝，将电极丝挂上导 轮、导电块、导轮喷水嘴等，最后往下悬臂挡丝棒，回到丝筒上并压紧，视操作熟练程度还 有其他上丝方法，这不再一一介绍。 Well-adjust the left and right link stoppers according to the cutting requirements. 根据切割要求调整好左、右撞块 While mounting the “Electrode Wire”, please pay close attention to the “Rotating Direction” of “Wire Tube” and “Moving Direction” of “Tool Carriage” in order to prevent the “Electrode Wire” from rushing out of Stroke. (Please be noted to take off “Swing Handle” in staring “Kinetic Wire Motor” in order to prevent it from rushing out and hurting the people.) 22 上丝时注意丝筒转向和拖板移动方向防止冲出行程(注意开运丝电机时必须取下摇手柄，以 防飞出伤人)。 When special circumstances occur such as the “Stroke Switch” is out of order etc., the “Wire tube” will dash out of the Stroke and cause separation between Nut and Lead-Screw. By this time, it should immediately shut off the “Control Switch” of the “Wire Tube”, slightly push forward the “Tool Carriage”, make the Lead-Screw contact the Nut End. (It is forbidden to use the over-large strength, otherwise it will damage Nut.) Meanwhile shake the “Wire Tube” by hand to slowly wrench “Lead-Screw” into Nut. 遇到特殊情况(如行程开关失灵)，丝筒就会冲出行程造成丝杠与螺母脱落，此时马上关闭 丝筒控制开关，然后轻轻推动拖板，使丝杠接触螺母端部(注意，用力过大会损坏螺母)， 同时用手摇动丝筒使丝杠缓缓拧入螺母即可。 Diagram 11 图11 Adjusting Bolt in Guide Rail Regulating Plate 导轨调节板调节螺钉 Page 13 第13页 Wire tightening wheel is used to tighten the wire by hand. After a period time of use, the electrode wire will be stretched and loosened because of fatigue. By this time, it needs to use the hand-operated wire tightening method to make the re-tensioning. Please pay attention to use the even strength. 紧丝轮用于手动紧丝，电极丝经过一段时间使用后，因为疲老产生拉长而变松，此时可用手 动紧丝方法可重新张紧，注意用力要均匀。 Guide Wheel Adjustment 导轮的调整 As it is as high as 11 meters / second of “Line Speed” of “Electrode Wire” which has been installed in “Guide Wheel and Wire-Positioning Wheel Assembly”, therefore it is also as high as 7000r.p.m,8000r.p.m. “Rotating Speed” to “Guide Wheel and Wire-Positioning Wheel Assembly”. So it requires high “Kinetic Accuracy” to them. “Wheel Guide and Wire-Positioning Wheel” should be of light weight, little inertia, fine wearability, sound insulation, good water-resistance. Because it has special function in the cutting process, therefore it is vital to “Work-Piece Accuracy and Roughness” etc. And it is extremely important to their adjustment. Please refer to 13 for the “Regulating Method”. “Radial Jump” of “Guide Wheel” (require 0.005) has mainly been controlled in the packaging. 导轮及排丝轮组件由于架在其上的电极丝线速度高达11米/秒，所以导轮与排丝轮组件转速 高达7000,8000转/分，这就要求它们有很高的运动精度。导轮及排丝轮必须重量轻，惯量 小，且要耐磨、绝缘、防水。由于其切割过程中起到特殊的作用，对工件精度、粗糙度等至 23 关重要，所以它们的调整就显得尤为重要。调整方法见13，导轮的径向跳动(要求0.005) 主要在其组装时就已得到了控制。 “Axial Displacement” of “Guide Wheel” (Allowance 0.002) mainly regulates Nut 1 and Nut 2. It should not only ensure the flexible rotation of “Guide Wheel”, but also have no “Axial Displacement” after the adjustment. It should add the enough “Lubricating Grease” in renewing the new “Guide Wheel” and Bearing. 导轮的轴向串动(允差0.002)主要是调节螺母1和螺母2，调节后既要保证导轮转动灵活， 又要无轴向串动。更换新导轮和轴承时则必须要加足高速润滑脂。 Nut 螺母 Guide wheel 导轮 Diagram 13 图13 Schematic Diagram of Guide-Wheel Wire-Positioning Wheel Adjustment 导轮排丝轮调整示意图 Work-Piece Chucking 工件装夹 Verticality between electrode wire and work-table should be corrected before chucking the work-piece. 装夹工件前应校正电极丝与工作台面垂直。 Fixed the jig into the work-table. 将夹具固定在工作台上。 It should use the gauge such as dial indicator etc. to find the right reference plane according to the drawing requirements. It should be parallel to X-directional or Y-directional worktable. 装夹工件时应根据图纸要求用百分表等量具找正基准面，使其与工作台的X向或Y向平行。 The chucking position should control the cutting range of the work-piece within the allowable stroke of the machine tool. 装夹位置应使工件的切割范围控制在机床的允许行程之内。 The work-piece and jig should not touch any part of the coil holder during the cutting process. 工件及夹具在切割过程中不应碰到线架的任何部分。 After the completion of the work-piece chucking, it should get rid of all the sundries in the 24 work-table. 工件装夹完毕要把工作台上的一切杂物清除干净。 Operation and points for attention: 操作及注意事项 Operational procedures: 操作步骤 Start “Machine Tool Master Mains Switch SQ”, meanwhile turn on three Switches of “HF Mains”, “Controller”, “24V Step Mains” at the same time, by this time, it displays red to three “Start Indicating Lamps” in “Control Panel” and it is bright to “Indicating Lamps” in three Positions. Various parts of the whole “Machine Tool” are in “Starting Conditions”. 开启机床总电源开关SQ，同时将控制器24V步进电源及高频电源三个开关也开启，此时控制面板上的三个开启指示灯显示红色，三个部位的指示灯皆亮，整台机床各部位处于起始状态。 Page 14 第14页 Input the Formulated Program (3B Modality) into the Controller. 将编好的程序(3B程式)输入控制器 Work-Piece Installation 工件安装 Penetrate through “Electrode Wire” (after it has been done, manually tighten the Wire once or twice with even strength) 穿电极丝(电极丝穿装好后应用手动紧丝一到二遍，紧丝时用力要均匀)。 Start “Kinetic Wire Motor” (Note: if it does not press one “Green Switch” of “HF Mains”, it can not start this Motor.) 开启运丝电机(注:高频电源一只绿色开关不按下，此电机将无法启开。) Open “Cooling Pump” and Regulate “Water-Jet Volume” 开冷却泵调节喷水量 When start the pump, please firstly regulate the Valve into “Shut-off Condition”, then gradually enlarges it until the “Upper and Lower Water-Jet Column” holds the “Electrode Wire”. 开泵时请先把阀调至关闭状态，然后逐渐加大调至上下喷水柱包容电极丝即可。 Start “High Frequency” to select “Electrical Parameters”, the consumer can make choice according to the requirements towards “Cutting Frequency” or “Surface Roughness” etc. (For detailed information, please refer to “Pulse Mains Sub-Manual of this Description”.) During the 25 electrode wire cut-in process, please relatively increase the distance of “Pulse Space”. And re-adjust the “Pulse Space” when it has stable conditions after Cut-in so that the “Machining Current” can meet the demands. 开高频选择电参数，用户可根据对切割频率或表面粗糙度等要求来选择(详见本说明书的脉 冲电源分册)，电极丝切入时请把脉冲间隔相对拉开，待切入后稳定时再调节脉冲间隔，使 加工电流满足要求。 Rotate “Wave-Form Switch” in “Control Cabinet” to “Automatic Machining Step”, start “Program Running”, i.e. start “X, Y Feeding Switch”, (U, V Feeding Switch should also be started for Taper Machining). When it enters into Cutting, regulate “Potentiometer Rotary Button”, observe “Machine Tool Amperometer” to stabilize the Pointer. (It allows only a little sway of Pointer). 将控制柜上的波段开关旋到自动加工档，启动程序运行，即开启X、Y的进给开关，(若有 锥度加工还应开启U、V进给开关)，进入切割时，要调节电位计旋钮，观察机床电流表使 指针稳定(允许指针略有晃动)。 After the Machining Completion, firstly shut off “Pulse Mains”, then switch off “Water Pump Power Supply” and “Kinetic Wire Tube Switch”. (Please be noted that “Wire Tube” should be shut off immediately after commutating. It is forbidden to close it after long time of commutating.) To check whether “X, Y Coordinate” have reached the “End Point” or not. If they have not reached “End Point”, it should examine if there is something wrong with Program or “Control Cabinet”. 加工结束应先关闭脉冲电源，然后关闭水泵电源，再关闭运丝筒开关(注意应在丝筒换向后 迅速关闭，不要在换向后太久关闭)，检查X、Y座标是否到终点，若未到终点就应检查程 序是否有错或控制柜是否有故障。 Points for Attention: 注意事项 Reasonably regulate the “Feeding Speed” according to “Work-Piece Thickness, Material Hardness” until it stabilizes Amperometer. If it is not sure, it can have the trial cutting first and then implement the formal cutting after well-adjustment. 根据工作厚度，材料硬度要合理调好进给速度，使电流表稳定为止，如没有把握，可先行试 割，待调好后再正式切割。 If it is not sure about the “Program Formulating” to “Complex Spares”, it can firstly implement the trial-cutting to thin sheet. 对于复杂零件的程序编制如无把握，可先用薄板试割。 If there is short-circuit circumstances in cutting such as none spark, none feeding cut etc., it can be removed by “Short-Circuit Backspace”. In addition, please don’t interrupt the operation to the best of the operator’s abilities, otherwise it will have “Machining Trace”. 切割中出现短路现象，(无火花、无进给切割)可用短路回退排除，另外在切割中应尽量不 要操作停机，以免出现加工痕迹。 26 It should have smoothly-circulated “Quench Liquid”, otherwise it easily causes “Broken Wire” or “Short-Circuit”. Please pay special attention to the point that it does not allow “Quench Liquid” to enter into “Machine Tool Running System”, otherwise it will be burnt. 冷却液一定要畅通，否则极易引起断丝或短路，工作中要特别注意冷却液不许进入机床电器，以免烧坏机床电器。 When “Concave Trace” occurs to “Conductive Block” or “Wire-Positioning Rod”, it should timely be regulated to new position, otherwise it will result in bad contact or broken “Electrode Wire”. 当导电块或挡丝棒表面出现凹痕时，应及时调整到新的位置，否则会发生接触不良或夹断电 极丝。 Machine Tool Maintenance & Trouble Removal 机床的维护与故障的排除 Machine Tool Maintenance 机床的维护 It should keep clean of the overall “Machine Tool”. It should also wipe clean the Machine with more than eight hours’ stop. It should be coated with oil to prevent it from rusting. 整机应保持清洁，停机8小时以上应揩抹干净，并涂油防锈。 It should frequently use kerosene to clean the “Guide Wheel”, “Wire-Positioning Wheel” in “Coil Holder” and the surrounding parts. Dirt oil after cleaning can not be leaked into “Back Water Groove” of “Work-Table”. 线架中的导轮及排丝轮周围应常用煤油清洗干净，清洗后的脏油不得漏至工作台的回水槽 内。 Complete set of Bearing and “Guide Wheel” should commonly be renewed after two to three months’ of use. (It can still use “Outer Cover of Copper Parts.) 导轮及轴承一般在使用2,3个月后应成套更换。(外套铜件仍可用) When “Power Supply Voltage” exceeds ?10% of Rated Voltage, it suggests externally connecting with “Voltage Stabilizing Mains” outside “Control Cabinet”. 当供电电压超过额定电压?10%时建议控制柜外接稳压电源。 Under conditions of strictly in accordance with “Two-Shift Work System” and “Use Rules & Regulations”, the “Machine Tool Accuracy” can be kept in about two years. 本机床在两班制及按照使用规则的条件下，其精度保持在二年左右。 Common Trouble & Removal Methods of Machine Tool (See Table 3) 机床的常见故障与排除。(见表三) Page 15 第15页 27 Table 3 表三 No. Problems in Causes Removal Methods No. Machining Causes Removal Methods 序加工中的问题 产生原因 排除方法 号 1 Broken It has Unstable Feeding, too quick It should be fewer Current Wire broken wire “Cut-in Speed” or overlarge and slightly slow in initial 断 when it Current “Cut-in Speed” 丝 starts 进给不稳，切入速度太快或电流刚切入时速度应稍慢，电流 wire-cutting.过大。 要小些。 刚开始切割 即断丝 “Quench Liquid” does not eject Search the Location of in time. “Cooling System” Trouble 冷却液没有及时喷出。 and promptly remove troubles Some “Electrode Wire” has been 查找冷却系统故障所在，及 coiled tightly in “Wire Tube” but 时排除。 some has been loosened which causes partially fierce It should immediately tighten wire-vibrating and even results in “Electrode Wire” and wire-breaking. overcome “Wire-Vibrating 电极丝在筒上缠绕紧松不一造Conditions”. 成局部抖丝厉害以致断裂。 应马上收紧电极丝，克服抖 丝现象。 Ineffective “Wire-Positioning Rod” results in Overlapping of Adjust “Wire-Positioning “Electrode Wire”. Rod” Location 挡丝棒没有发挥作用，造成电极调整挡丝棒位置。 丝叠丝。 Get rid of Work-Piece “Work-Piece Surface” has burr, Surface Burr and Oxidized oxidized skin and sharp edge. Skin 工件表面有毛刺，氧化皮及锐边 清除工作表面毛刺及氧化 皮。 28 It suddenly “Wire-Breaking in Wire-Tube Timely remove trouble of breaks the Commutating” is mainly caused non-disconnection of HF wires during by not synchronously cut off “HF Mains the cutting Power Supply”. It results in the 及时排除高频电源不切断 process. burnt “Electrode Wire”. 的故障。 在切割过程丝筒换向时断丝主要是高频电 中突然断丝 源没有同步切断，致使烧断电极It should have even 丝。 “Work-Piece Material” and remove Stress inside It causes deformation by uneven “Work-Piece” to the greatest “Work-Piece Material Tissue”. extent. It breaks “Electrode Wire” in 工件材质要力求均匀，尽量 clamping. 消除工件内应力。 工件材料组织不均匀产生变形， 夹断电极丝。 Correctly choose “Electric Gauge” Improper match between 正确选择电规准。 “Work-Piece Thickness” and “Electric Gauge Selection”. Reasonably formulate 工件厚度与电规准选择配合不Concentration and frequently 当。 keep clean of “Working Solution” Improper Use of “Quench 合理配制浓度，经常保持工 Liquid”, it is too diluted, or dirty 作液清洁。 or of too small flow. 冷却液使用不当，太稀或太脏或Renew “Electrode Wire” 流量太小。 更换电极丝。 “Electrode Wire” has been used for too long. It gets aged or crispy. 电极丝使用时间过长、老化、发 脆。 2 There is obvious wire Loosened or vibrating “Electrode Remove according to trace in the surface of Wire” “Wire-Loosening Method” work-piece. 电极丝松动或抖动。 按松丝方法排除。 工件表面有明显丝痕 Large sway of “Guide Wheel” or Remove sway and put no “Center Alignment” between “Electrode Wire” in center “Upper and Lower Parts” position of “Guide Wheel 导轮窜动大或上下不对中。 Groove” 消除窜动，使电极丝在导轮 No elimination of axial clearance 槽中间位置。 between “Work-Table” and 29 “Wire-Tube Tool Carriage” Adjust clearance between 工作台及丝筒拖板轴向间隙未Nut and “Lead-Screw” 消除。 调整丝杠与丝母间隙。 Unstable tracking Electric Gauge Adjustment 跟踪不稳定。 & HF Tracking 调节电规准及高频跟踪。 Too dirty or improper selection of “Quench Liquid” Renew “Quench Liquid” 冷却液选择不当或太脏。 更换冷却液。 3 “Guide Wheel” skips Large Guide Wheel Axial Regulate Clearance with whistle, or not Clearance 调整间隙。 flexible rotation 导轮轴向间隙大。 导轮跳动有啸叫声或 Clean Bearing by Gasoline 转动不灵活 “Quench Liquid” enters into 用汽油清洗轴承。 Bearing 冷却液进入轴承。 Renew Bearing and Guide Wheel It decreases “Bearing Accuracy” 更换轴承与导轮。 and wears away “Guide Wheel” in long-term use. 长期使用轴承精度降低、导轮磨 损。 4 It does not conform Radial Skip of “Coil Holder It should elaborately with “Machining Guide Wheel” and Axial Sway regulate kinetic Accuracy”. Out-of-Tolerance requiremetns from “Guide 加工精度不符 线架导轮径向跳动与轴向窜动Wheel”. 超差。 应精心调整导轮运动要求。 Large Back-Lash of Drive Gear Adjust “Installation Position 传动齿轮啮合间隙大。 of Step-Motor” to make even Clearance Bad Verticality between Upper 调整步进电机安装位置使 and Lower Work-Tables 间隙均匀。 上下工作台垂直度不好。 It should make It results in out-of-step from re-adjustment. over-small “Step-Motor Static 应重新调整。 Moment”. 步进电机静态力矩过小造成失It should check whether it is 步。 normal or not to “Step-Motor” and “24V Drive Voltage”. 须检查步进电机及24V驱 30 动电压是否正常。 5 Burnt Work-Piece Improper Selection of HF Mains Regulate “Electric Gauge” Surface Electric Gauge 调整电规准。 工件表面烧伤 高频电源电规准选择不当。 Examine “Control Box” It is not sensitive to “Automatic 检查控制箱。 Frequency Modulation”. 自动调频不灵敏。 Renew “Quench Liquid” 更换冷却液。 Too dirty or lack of “Quench Liquid” Supply 冷却液供应不足或太脏。 Page 16 第16页 Vulnerable spare table: 易损零件表 Name Installation Position Quantity 名称 安装部位 数量 Guide Wheel Combination Coil Holder 2 导轮组合 线架 Wire-Positioning Wheel Coil Holder 2 Combination 线架 排丝轮组合 Wire-Positioning Rod Coil Holder 1 挡丝棒 线架 Conductive Block Coil Holder 2 Combination 线架 导电块组合 Coupler Elastic Ring In Kinetic 3 联轴器弹性圈 Wire Component Coupler. 运丝部件联轴器内 Page 17 第17页 Machine Tool Running System Installation & Use Description 机床电器安装及使用说明 Components 部件 31 “Wire-Cutting Machine Tool Running System” is divided into the following components: 线切割机床电器系统分以下部件 Machine Tool Running System Box 机床电器箱 Wire Tube Induction Switch Assembly 丝筒感应开关组件 Wire Storage Tube Open / Shut, Water Pump Open / Shut, Broken Wire Protection, Operation Panel 开丝筒开水泵断丝保护操作面板 2M 6-Core 2510 Cable, 2M 8-Core 2510 Cable, Plug-in Unit Fittings 2米6芯2510电缆，2米8芯2510电缆，插件附件 Three-Phase Four-Wire Inlet 三相四线进线 Wire tube 丝筒 Water pump 水泵 HF control 高频控制 Connect with operational panel 接操作面板 Connect with induction switch 接感应开关 8A safety tube holder 8A保险管座 Brake energy control 刹车能量控制 Diagram 1-1 图1-1 32 Page 18 第18页 Switch-in diagram 接入图 Three-phase wire inlet switch-in diagram 三相进线接入图 The wire tube will make the automatic brake while pressing down Emergency-Stop Switch or under power-failure conditions. 急停开关按下或断电时丝筒会自动刹车 C-phase C相 B-phase B相 A-phase A相 Zero line 零线 Emergency Stop Switch 急停开关 HF Control Wire-Connecting Diagram 高频控制接线图 Commutating 换向 HF Stop 停高频 Port 端口 Completion Stop 结束停 Tail Conductive Block 33 尾导电块 Front Conductive Block 前导电块 Working Lamp 工作灯 Description: 说明 ? end should connect with tail conductive block. ?端一定要接尾导电块 ? end should connect with front conductive block. ?端一定要接前导电块 (I.e. Discharge Conductive Block) (即放电导电块) Page 19 第19页 Induction Switch 感应开关 Left 左 Stop 停 Right 右 Description 说明 When metal is close to Induction Switch, the corresponding LED lamp in Switch will shine. 金属接近感应开关时，对应在开关中的LED灯会发光 Wire Tube Leftward Running Inching Switch 丝筒左向运转点动开关 34 Wire Storage Tube Stop Switch 停车开关 Wire Tube Rightward Running Inching Switch 丝筒右向运转点动开关 Diagram 3-1 图3-1 Operation Panel Wire-Collecting Block 操作面板集线块 Wire Tube Switch and LED Plug-in Unit 丝筒开关及LED插件 Water-Pump Switch & Plug-in Unit 水泵开关及LED插件 Broken Wire Stop & LED Plug-in Unit 断丝停及LED插件 Change to Indicating Lamp Plug-in Unit 改作指示灯插件 Connect with Control Box Wire & Cable Plug-in Unit 接控制盒线缆插件 thSocket 1 Corresponds20-Core Rectangular 11 Foot to 插座1对应20芯矩形11脚 Diagram 4-1 图4-1 Page 20 第20页 Wire-Connecting Method of Operation Switch 操作开关连线方法 Please Refer to Diagram 4-1 参见图4-1 “Wire-Connecting Mode” of A/B Wire Tube, Water Pump Plug-in Unit. “One-Time Press of Switch” controls “Motor Start / Stop”. 35 A/B丝筒、水泵插件接线方式，开关按动一次控制电机起/停。 Broken Wire Stop Switch Wire-Connecting Mode, when it is in “SW Open-Circuit”, it is ineffective to “Broken Wire Stop”. It should short-circuit LED Terminal when it has no LED. 断丝停开关接线方式，当SW开路时断丝停无效当没有LED时应将LED端短路 Mains Indication LED Mains Indication LED 电源指示LED Brake Energy Control 刹车能量控制 Under “Three-Phase Power-off Conditions”, it should firstly adjust the Potentiometer in “Control Box”, and then restore “Three-Phase Power”, it possibly regulates “Brake Energy”. 在三相断电条件下，调整控制盒上的电位器然后再恢复三相电，可能调节刹车制动的能量。 Page 21 第21页 Conceptual Diagram of Systematic Wire-Connection 系统接线示意。 Induction Switch 感应开关 C-Phase C相 B-Phase B相 A-Phase A相 Zero Line 零线 Wire Tube 丝筒 Water Pump 水泵 36 HF Control 高频控制 Broken Wire Switch-in 断丝接入 Completion Stop Switch-in 结束停接入 Working Lamp Output 工作灯输出 Operational Wire-Collecting Block 操作集线块 Page 22 第22页 Operational description: 操作说明 Wire tube switch opens and shuts the wire tube according to the work-mode. 丝筒开关根据工作模式，开启和关闭丝筒。 “Water Pump Switch” starts and closes “Water Pump” according to “Work Mode”. (Note: Before installing Wire, it should cancel “Broken Wire Protection. I.e. It has dark LED and “Open-Circuit” of “Broken Wire Protection Switch”.) 水泵开关根据工作模式，开启和关闭水泵，(注:没有上丝时，应将断丝保护取消——断丝保护开关开路、LED不亮) “Induction Switch Assembly” is used to install and tighten Wire, induce “Wire Tube Position” and make Commutation. 感应开关组件用于上丝、紧丝及感应丝筒位置及换向。 Page 23 第23页 Chapter One 第一章 Brief summary to the machine tool running system and control system 电器控制系统概述 “Contactor Relay” is the main component of “Wire-Cutting Running System” and “Machine Tool 37 Running System” Parts which have been produced by this Company. It adopts “Simens” Running System which is a famous brand in the world. In this way, it greatly increases the service life of the “Running System”. “HF Pulse Mains” takes “Crystal Oscillator” as the “Oscillating Source”. It has the extremely stable frequency. The complete set of the “Running System” adopts digital integrated circuit to produce the Pulse. In this way, it guarantees the long-term stable running of the “Power Source”. 本公司生产的线切割电器、机床电器部分的主要器件接触器式继电器，采用世界名牌西门子电器，这样使电器的使用寿命有了很大的提高，高频脉冲电源以晶振为振源，频率极其稳定，整套电器全部采用数字集成电路来产生脉冲，这样保证了电源能长期稳定的运行。 Machine tool running system 机床电器 Machine tool running system mainly consists of the machine tool running system switch box, stroke switch, wire-traveling motor, water pump motor, X and Y step-motors, U and Y step-motors with taper. The machine tool running system utilizes the contact of the contactor to control the running of the machine tool and other running systems. It uses the circuit-breaker and fuse to function as protection. 机床电器主要包括机床电器开关箱、行程开关、走丝电机、水泵电机、X、Y步进电机，及带锥度的U、Y步进电机。机床电器是利用接触器的触点来控制机床及其它电器的运行，并采用断路器、熔断器作保护。 “Kinetic Wire” in “Wire Storage Tube” has been driven by “Motor M”. “X and Y Tool 2 Carriage” have respectively spurred on by “X and Y Step-Motor”. There are “Four Tool Carriages of X, Y, U, V” for “Taper Machine Tool”. “U and V” have respectively driven by “U and V Step-Motor”. Emulsion has been supplied by “Water Pump Motor M1”. 贮丝筒的运丝由电机M带动，X、Y两个拖板分别由X、Y步进电机带动，锥度机床有X、2 Y、U、V四个拖板，U、V分别由U、V步进电机带动，乳化液由水泵电机M1供给。 Main Technical Parameters 主要技术参数 Name Model Mains Voltage Wattage 名称 型号 供电电压 功率 Water-Pump YB-25G AC Three-Phase 120W Motor 380V 水泵电机 AC三相380V Wire-Traveling A02-7124 AC Three-Phase 370W Motor 380V 走丝电机 AC三相380V Step-Motor 75BC003 DC24V 步进电机 Contactor 3TH82-62 AC220V 接触器 38 Machine Tool Running System Operation Panel Description 机床电器机板说明 Emergency Stop 急停 Mode 模式 Kinetic Wire 运丝 Water Pump 水泵 Zhongyuan Machine Tool Co., Ltd. 中原机床有限公司 Emergency Stop Switch 急停开关 Master Mains Indicating Lamp 总电源指示灯 Mode Switch 模式开关 Wire-Traveling Open 走丝开 Wire-Traveling Open Indicating Lamp 走丝开指示灯 Wire-Traveling Shut 走丝关 Water-Pump Open 水泵开 Water-Pump Open Indicating Lamp 水泵开指示灯 Water-Pump Shut 39 水泵关 Page 24 第24页 Operational Description to Machine Tool Running System 机床电器操作说明 Plug in 380V three-phase AC mains, then turn on “Main Power Supply Switch” in the left of “Machine Tool Running System Cabinet”, it is bright to “Main Power Supply Indicating Lamp”. “Wire-Traveling Motor”, “Water-Pump Water” have respectively been controlled by “Two-Group Press Button”. Green for Open and Red for Shut. “Indicating Lamp” is bright under “Open Conditions” and dark under “Shut Conditions”. We hereby remind the consumers that when “Mode Switch Lamp” is under “Shut Conditions”, “Broken-Wire Protection” and “Machine Stop after Machining” will give function. 接入380V三相交流电源，然后拉起电器箱左边的总电源开关，这时总电源指示灯亮。走丝 电机、水泵电机分别由二组按钮控制，绿色为开、红色为关，开启时指示灯亮，关闭时指示灯灭。要提醒用户的是只有当模式开关灯在关的状态时，断丝保护及加工完停机起作用。 Pulse Power Supply 脉冲电源 This power supply is composed of “Master-Oscillating Circuit”, “Pulse-Width Regulating Circuit”, “Clearance Regulating Circuit”, “Power Amplification Circuit”, “Commutating Circuit” etc. 本电源由主振电路、脉宽调节电路、间隙调节电路、功率放大电路和整流电路等构成。 “Master-Oscillating Circuit” produces dominant frequency pulse by “Crystal Oscillator”. It outputs wave-release pulse through “Frequency-Division Circuit”. When the Switch chooses “Rectangular Pulse Wave-Form”, “Square Wave” inputs “Pulse-Width Regulating Circuit”. By this time, “AND gate” output wave-form has been regulated by the required Switch through “Pulse Width” and “Clearance Adjustable Circuit”. “Pulse Width Regulation” has been selected through “Four Single-Pole Single-Throw Switch”. After Wave-Form has been pre-amplified, it drives “Power Amplification Tube” and outputs the tidy and stable “Machining Signal”. 主振电路由晶体振荡器产生主频脉冲，经分频电路输出放波脉冲。当开关选择矩形脉冲波形时，方波输入脉宽调节电路，此时，与门输出的波形是经脉宽和间隙调节电路按所需开关调节。脉冲宽度调节由4只单刀一掷开关选择，调节量为4μS(正常时)或8μS(倍宽时)。脉冲间隙由4只单刀一掷开关选择。波形经前置放大后，驱动功放管，输出稳定整齐的加工信号。 “Power Amplification Circuit” adopts the imported VMOS Tube. Six “Power Amplification Switches” are available for work selection. 功率放大电路采用进口VMOS管，六只开关选择工作。 Major Technical Parameters 40 主要技术参数 Operating Power Supply: AC220?10%V 50?10Hz 使用电源:交流220?10%V 50?10Hz Rated Power: 800W 额定功率:800W Pulse Parameters 脉冲参数 Rectangular Pulse 矩形脉冲 Grouping Pulse 分组脉冲 Machining Voltage: 70,120V Adjustable 加工电压:70,120V可调 Max. Machining Current: 6.5A 最大加工电流:6.5A Wattage Output: 6-Step Adjustable 功率输出:6级可调 Max. cutting thickness: ?400mm 最大切割厚度:?400mm 2Max. cutting speed: ?1200mm/hm 2最大切割速度:?1200mm/hm Pulse mains panel description 脉冲电源面板说明 Upper-on and lower-off to all switches 所有开关上开下关 Page 25 第25页 Voltmeter 电压表 41 Amperometer 电流表 Pulse wave-form regulating switch 脉冲波形调节开关 Power Amplification Switch 功放开关 Mains switch 电源开关 HF output test interface 高频输出测试接口 Voltage regulating switch 电压调节开关 Fuse 保险丝 Mains wire inlet socket 电源进线插座 Operational description of the pulse mains 脉冲电源操作说明 Switch on the Mains Switch in the panel, it is bright to the indicating lamp, it runs the fan on the left of the cabinet, it means that it has input AC200V power supply. Choose the machining voltage, the voltage is divided into five adjustable steps ranging from 70V to 120V. Switch on Band Selector, the indicating value of the voltmeter is the peak value of the machining voltage. 接通面板上的电源开关，指示灯点亮，机箱左边的风扇运转，表示交流200V电源已输入。 选择加工电压，电压在70,120V之间分五档可调，拨动波段开关，电压表指示值即为加工 电压幅值。 In general, it should choose 70V to the work-piece whose thickness is less than 5cm; 80,90V to that with 5cm,15cm thickness and 120V to that with higher than 400cm thickness. 对一般厚度5厘米以下的工件电压选择为70V，对厚度5厘米以上15厘米以下一般选择80, 90V为宜，高于400厘米选择120V。 There are six “Wattage Output Switches”. “Power Amplification Tubes” have respectively controlled by six Switches. It can flexibly regulate the “Peak Current功 of “Output Pulse”. It ensures that it can get the required “Average Machining Current” upon various technological requirements. 42 率输出开关为6只，功放管分别由6只开关控制，能灵活地调节输出脉冲的峰值电流，保证在各种不同的工艺要求下，获得所需要的平均加工电流。 “Pulse Wave-Form Selection Switch” is in Rectangular Position. It outputs “Rectangular Pulse”. It is used in “High-Speed Machining”. Switch is in “Grouping Position”. It outputs “Grouping Pulse”. It is used in “Precision Machining”. “Pulse Width Selection” are five Switches which are respectively “Double Width / Normal Switch”, “4μS”, “8μS”, “16μS”, “32μS”. The calculation mode of “Normal Pulse Width” is in “Adding Form”. The calculation mode of “Double-Width” is “Multiple of Added Value”. 脉冲波形选择开关打在矩形位置，输出矩形脉冲，可用于高速加工;开关打在分组位置，输出分组脉冲，可用于精密加工。脉宽选择为5只开关，分别是倍宽/正常开关，4μS、8μS、16μS、32μS，正常脉宽的计算方式为相加形式，倍宽的计算方式为相加值的倍数。 For example: 例如: When it closes “8S and 16S Switch”, “Pulse Width” is “8+16=24μS”. When it closes “8μS, 16μS and Double Width Switch”, “Pulse Width (8+6)?2=48μS”. The rest can be inferred from this. “Max. Pulse Width” is (4+8+16+32)?2=120S. When Waveform is “Rectangular Pulse”, “Pulse Width” is the “Actually-Calculated Value”. When Waveform is “Grouping Pulse”, “Pulse Width Ti Numeric Value” is “Calculated Value” times 4. (By this time it is ineffective to “Double Width Switch.”) “Pulse Space Selection” has been controlled by “Single-Pole Single-Throw Switch”. It has four Switches for your choice. It has no output to “1μS and 2μS Switch”. It should be matched with 4μS or 8μS. 当合上8S、16S开关时，脉宽是8+16=24μS;当合上8μS、16μS和倍宽开关时，脉宽(8+6)?2=48μS，依次类推，最大脉宽是(4+8+16+32)?2=120S，当波形为矩形脉冲时，脉宽即为实际计算值;当波形为分组脉冲时，脉宽Ti数值为计算值乘4(此时倍宽开关不起作用)。脉冲间隔选择是由单刀一掷开关控制，有4只开关可供选择，1μS、2μS开关没有输出，一定要同4μS或8μS搭配。 Page 26 第26页 Pulse Width Selection 脉冲宽度的选择 The more wider the “Pulse Width” is, the much larger the “Single Pulse Energy” and higher “Cutting Efficiency” will be. As it has long discharging period, it brings about the stable Machining, but weak “Surface Roughness” as well. If it intends to get the fine “Surface Roughness”, it should choose narrow “Pulse Width”, therefore it would result in fewer “Single Pulse Energy”. Whereas it would also result in comparatively weak “Machining Stability” because of short discharging period. So the users can select the proper “Pulse Height” according to the above-mentioned features in accordance with their specific requirements. 脉冲宽度越宽，单个脉冲的能量就越大，切割效率也就越高，由于放电时间长，所以加工较 43 稳定，但表面粗糙度就差些。若要表面粗糙度好则应选用窄脉宽，这样单个脉冲的能量就小， 但由于放电时间短，加工稳定性也就差一点。因此用户应根据不同的要求，按照上述特点选 择合适的脉冲高度。 Pulse clearance selection 脉冲间隙的选择 Because it is difficult to remove chips from the large-thickness “Work-Pieces”, therefore it needs to properly enlarge the “Pulse Interval Time”. It grants the relatively ample period for chip-removal on the one hand, and reduces some dirty and corrosive substances on the other hand. It prevents from wire-breaking and brings about the stable Machining. Therefore it commonly requires the direct proportion between the “Pulse Clearance” and “Work-Piece Thickness”. Please draw reference from the below Table for your wise selection. 由于厚度大的工件排屑困难，因此就需要适当加大脉冲间隔时间，这样一方面是给排屑有较 充裕的时间，另一方面减少生成一些蚀污物;防止断丝，使得加工较稳定。所以一般要求脉 冲间隙与工件厚度成正比。可参考下面表格进行选择。 Power Amplification Tube Selection 功放管的选择 “Power Amplification Tube” is of parallel use. The more the “Power Amplification Tube”, the larger the “Machining Current” and the quicker the “Machining Speed” is. But under conditions of same “Pulse Width”, the larger the “Machining Current”, the weaker the “Surface Roughness” will be. When it chooses “4μS Narrow Pulse Width” for the “Finish Machining”, in order to ensure the “Machining Stability”, if the “Work-Piece” is relatively thick, it should turn on some more “Power Amplification Tubes”. The reason is that, when it has fewer “Power Amplification Tubes”, it results in fewer adding volume of “Single Pulse”, therefore it will easily cause “Short-Circuit”, it is impossible to have stable Machining also. If it only requires high speed, but it does not demand high “Surface Roughness”, it can throw in much more “Power Amplification Tubes” for Machining. It can draw reference from below Table for wise selection. 功放管是并联使用的，功放管数选得越多，加工电流就越大，加工速度也就越快一些，但在 同一脉冲宽度下，加工电流越大表面粗糙度也就越差。当选用4μS窄脉宽进行精加工时， 为了保证加工稳定性，如果工件较厚时，功放管应多开几只，因为功放管少时，单个脉冲加 量少，这样就容易发生短路，无法稳定加工，如果只要求高速而表面粗糙度要求不高时，也 可以投入较多的功放管进行加工，可参考下面表格进行选择。 24V Step-Motor Drive Mains 24伏步进电机驱动电源 “24V Step-Motor Drive Mains” transforms “220V AC” through the Transformer and then rectifies through Diode to be changed into “DC24V Power Source” which acts as “Operating Mains” for “Step-Motor”. 24伏步进电机驱动电源，是把220伏交流通过变压器变压再经过二极管整流，变成直流24 伏电源供给步进电机作工作电源。 44 Main technical parameters 主要技术参数 Operating power supply: AC220V?10%V 50?10%Hz 使用电源:交流220V?10%V 50?10%Hz Rated wattage: 300W (taper 500W) 额定功率:300W(锥度500W) Voltage with load: 24,26V 带负载电压:24,26V No-load voltage: 30V 空载电压:30V Operational Description of 24V Power Supply 24伏电源的操作说明 Page 27 第27页 Voltmeter 电压表 Mains Switch 电源开关 Fuse 保险丝 Mains Socket 电源插座 Rectangular Socket 矩形座 25V output 25伏输出 Operational description of 24V power supply 24伏电源的操作说明 It is relatively most simple to 24V mains operation. It only needs to plug in 220V power cord, 45 connect three corresponding plugs, switch on “Mains Switch”, and then it is bright to “Indicating Lamp”. 24伏电源的操作相比较而言是最简单的，只要插入220V电源线，连好相对应的三个插头， 打开电源开关，指示灯亮即可。 Chapter Two 第二章 Common Troubles of “Machine Tool Running System”: Causes and Removals 电器常见故障:原因及排除 Machine Tool Running System 机床电器 It is not bright to mains indicating lamp or the machine can not get started. 电源指示灯不亮或机器不能起动 When it closes “Master Mains Switch”, it finds out that it is dark to “Indicating Lamp” or it can not get started, it is mainly caused by “Three-Phase Mains Phase-Failure” or too low voltage of certain phase. It should detect “Three-Phase Voltage”. 合上总电源开关发现指示灯不亮或不能启动，主要是三相电源缺相或某相电压太低引起，检 测三相电压。 Non-operation of wire-traveling motor 走丝电机不运转 Open “Machine Tool Running System Box”, check it has simultaneous pick-up to Contact KA, KM2 (or KM3) or not. If none of them picks up, check whether it presses “Emergency Stop Switch” or not, test whether it has “220V Voltage” to “KA Coil Terminal” or not. If it has Voltage, it should change KA. If it has simultaneous pick-up to KA, KM2 (or KM3), it should check whether it has “Three-Phase Voltage” in the “Electric Motor” or not. If it has normal Voltage, it should change the “Electric Motor”. 打开机床电器箱，检查接触器KA，KM2(或KM3)是否同时吸合，如果一个都不吸合， 检查急停开关是否按下，测KA线圈端是否有220V电压，如果有电压需换KA。KA、KM2 (或KM3)同时吸合，则需测电动机上是否有三相电压，如电压正常时则需更换电动机。 Non-operation of water-pump motor 水泵电机不工作 Check whether “Contactor KM1” picks up or not. If it does not, test whether it has “220V Voltage” to two ends of “KM1 Coil” or not. If it has Voltage, it should change KM1. 检查接触器KM1是否吸合，如果没吸，测KM1线圈二端是否有220V电压，如有电压需要 换KM1。 46 If KM1 picks up, it should check whether it has “Three-Phase Voltage” to “Electric Motor” or not. If Voltage is in normal condition, it should renew the “Electric Motor”. KM1吸合，则需检查电动机是否有三相电压，如果电压正常需要更换电动机。 The sudden and frequent stop of “Wire-Traveling Motor” is commonly caused by too large fluctuation of “Three-Phase Voltage” or too low Voltage. Bad contact of “Wire Inlet and Outlet Plugs” is also one of the causes. 走丝电机经常突然停机，一般是因三相电压波动太大或电压太低，进线插头接触不良也是其 中原因之一。 If it has no brake from “Wire-Traveling Motor”, firstly it should check “1A Fuse”. If it has broken fuse, it need not have to immediately change Fuse, otherwise it will cause re-fusing of the Fuse. Firstly check whether Diode has been punctured or not and renew the Diode. (Note: It can not use higher than 1A Fuse, otherwise it burns the “Electric Wire”!) 走丝电机没有刹车，首先应检查1A保险丝，如果保险丝断，不要马上换保险丝，这样可能 引起保险丝再次熔断，首先检查二极管是否击穿，调换二极管。(注:保险丝不能用1A以 上，否则将引起电线烧掉～) It can not commutate from “Wire-Traveling Motor”. 走丝电机不能换向 Press by hand “Left and Right two Commutating Switches”, KM2 and KM3 Contactors should pick up in turn. If it finds out that one of “Switch Contactor” can not make Pick-up, it should check whether it has good condition to “Commutating Switch” or not. If Switch is in normal condition, then check whether it has 220V to two ends of “Contactor Coil” or not. If Voltage is in normal condition, then it should change the Contactor. 用手按动左右二只换向开关，接触器KM2与KM3两只接触器应轮回吸合，如果发现按动 其中一只开关接触器不会吸合，应检查换向开关是否良好，如果开关正常，然后检查接触器 线圈二端是否有220V电压，如果电压正常，需要换接触器。 Page 28 第28页 It is ineffective to “Broken Wire Protection”. 断丝保护不起作用 It is ineffective to “Broken Wire Protection”. It is commonly because of the over-dirty “Conductive Block” from too-long period of use. It results in the damaged “Conductive Block” and “Machine Tool Insulation”. Then it is ineffective to “Broken Wire Protection”. If you intend to distinguish what causes the “Ineffective Broken Wire Protection”, the simple method is to loosen the above Nut in the lower part of “Conductive Block”, take off the Conductor, by this time it can not start the Machine Tool. (“Mode Switch” should be in “Shut-off Position”.) It shows that it is effective to “Running System Circuit” of “Broken Wire Protection”. It only 47 needs to clean the “Upper and Lower Conductive Blocks”. 断丝保护不起作用，一般是因使用时间过长导电块过脏，造成导电块与机床绝缘被破坏。这 样断丝保护就不起作用，要区别是什么原因造成断丝保护不起作用，方法很简单，只要把下 导电块上面的螺母松开，取下导线，这时机床应不能起动(模式开关应在关的位置)。这样 说明断线保护的电器线路是起作用的，只要把上下导电块清洗一遍就可以了。 “Machine Tool” can not be started under “Shut-off Conditions” of “Mode Switch”. 模式开关在关状态机床不能启动 “Machine Tool” can not be started under “Shut-off Conditions” of “Mode Switch”. Firstly check whether it has sound contact between “Molybdenum Wire” and “Upper and Lower Conductive Blocks”, whether “Lead out Wire” has been loosened or not. Then examine whether or not “Molybdenum Wire” cuts off the Conductor that connects “Upper & Lower Conductive Blocks” with “Machine Tool Running System Cabinet”. If all the above are in good condition, then it needs to change “Broken Wire Protection” and “Master Stop Control Panel”. 模式开关在关状态机床不能启动，首先要检查上下导电块与钼丝之间的接触是否良好，导电 块的引出线是否松开。然后检查上下导电块与机床电器箱连接的导线是否被钼丝割断。如果 这些都完好就需调换断丝保护及总停控制板。 High frequency power source 高频电源 It is not bright to the mains indicating lamp 电源指示灯不亮 Examine if there is sound contact to the wire inlet socket, whether the fuse has been burnt or not, whether there is any breakdown to the full-bridge rectifier and filter chemical condenser or not. 检查进线插头接触是否良好，保险丝是否烧断，如果保险丝烧断，需检查全桥整流器及滤波 电解电容器是否击穿。 It has voltage display but no high frequency output. 有电压显示没有高频输出。 Two trouble possibilities would cause none HF output, i.e. there is defect to HF itself, or the controller has no switch to control high frequency, there is trouble to the voltage output and connecting cord. The check methods are as follows: 没有高频输出，故障有两种可能，一种是高频本身有故障，另一种是控制器无控制高频开关， 电压输出及连接线有故障，检查方法如下: Shut off “High Frequency Mains Switch”, use the Conductor to short-circuit the “Work-Piece in Panel” and two “Binding Posts” of “Molybdenum Wire”, it can only start one “Power Amplification Switch”, then turn on “HF Mains Switch”, start “Machine Tool Kinetic Wire Electric Motor”, turn on “Controller HF Control Switch”, by this time it should have “Current Display” in Amperometer. If it has no “Current Display”, it should check whether it will pick up 48 “Control Relay” in “HF Power Supply” or not. If it can, examine whether “HF Control Circuit” has normal condition or not. If it can not, check whether it damages “7812 Three-Terminal Voltage Stabilizing Block” in aspects of Drive or not, whether it damages “Machine Tool Controller HF Switch” or not, whether it has sound contact of “Wire Plug” or not, Whether it has good contact to “KM2, KM3, KM4 Contactor Tips” or not, Whether the Controller has “Control Voltage Output” or not. 关闭高频电源开关，用导线把面板上的工件与钼丝两只接线柱短接，只能开1只功放开关。然后打开高频电源开关，启动机床运丝电动机，打开控制器高频控制开关，这时电流表应有电流显示，如没有电流显示应检查高频电源里面的控制继电器是否会吸，如会吸检查高频控制电路是否正常。不会吸检查驱动上的7812三端稳压块是否损坏，单板机高频开关是否损坏，就要检查线插头是否接触良好，KM2、KM3、KM4接触器触点是否接触良好，及控制器是否有控制电压输出。 It has no Current or has overlarge Current to certain Step of “Power Amplification Switch”. 功放开关某档电流过大或没有电流 If it has no current or it is overlarge to certain step of current, and other steps are in normal condition, it shows that there is something wrong to only certain “Power Amplification Circuit”. It should check whether or not it damages “Power Amplification Tube”, “Diode”, “Voltage Stabilizing Tube” of this “Power Amplification Circuit” and then make due renewal. If it temporarily has no same kind of “Power Amplification Tube”, it should shut off this “Power Amplification Tube Switch”. It can still use the others. 某档电流过大或没有电流，其它各档都正常，说明振荡线路是正常的，只是某个功放线路出问题，应检查该功放线路的功放管，二极管及稳压管是否损坏，查出以后更换即可。若暂时无同类功放管，则关掉该功放管开关，其它仍可使用。 24V Step-Motor Drive Mains 24伏步进电机驱动电源 Step-Motor can not be Locked 步进电机锁不住 Page 29 第29页 “Step-Motor” can not be locked. Firstly check whether “24V Mains Switch” has been turned on or not, whether it is bright to “Mains Indicating Lamp” or not. If it is dark to “Indicating Lamp”, firstly examine whether Fuse has been burnt or not. If it is so, then check whether “Full Bridge Rectifier” and “Filter Electrolytic Capacitor” have been broken down or not, thirdly re-install Fuse. If it is in normal condition to the above, then check whether it has sound contact to the Plug or not, and whether “Step-Motor” has been disconnected or not. 步进电机锁不住，首先检查24伏电源开关是否打开，电源指示灯是否点亮，指示灯不亮，要先检查保险丝是否烧断，如果保险丝已断要检查全桥整流器及滤波电解电容器是否击穿，然后再装保险丝。如果上述都正常就要检查插头是否接触良好，步进电机是否断路: 49 Step-Motor is out of step. 步进电机失步 There are two possibilities to out-of-step of “Step-Motor”. One is “Controller Output Phase-Failure”. The other is “Drive Mains Trouble” which can result in damaged “Certain Group of Coil” in “Step-Motor”. 步进电机失步有两种可能，一种是控制器输出缺相，另一种是驱动电源故障可使步进电机某 组线圈坏。 Firstly confirm whether the Controller has “Output Phase-Failure” or not. For detailed information, please refer to (?) “Micro-Computer Control Repair”. “Normal Control” depends on “Drive Mains” or “Step-Motor”. If you intend to distinguish whether “Drive Mains” has problem or not, only insert “X-Shaft Step-Motor Plug” into “Y-Shaft Step-Motor” to test the conclusion. For example, Previously “X-Shaft” is out of step, well then insert “X-Shaft Plug” into “Y-Shaft”, if “Y-Shaft” is in normal condition, it shows that “Drive Part” is in normal condition. Then it needs to check whether it has sound plug contact or not, whether “Step-Motor” is in normal condition or not. Contrarily, it should examine whether or not it has sound contact between plug and socket of “26-Core Side Wire” and whether “8.2Ω Resistance” has broken circuit or not. 先要确定是否控制器输出缺相，详细请看(四)微机控制维修。如果控制要正常，问题就出 在驱动电源或步进电机上，要区别是否是驱动电源问题只要把X轴的步进电机插头插到Y 轴步进电机上去试一下，便可得出结论。例如:原来X轴是失步的，那么就把X轴的插头 插到Y轴上去，如果这样Y轴正常则说明驱动部分是正常的，需检查插头的接触是否良好， 步进电机是否正常;反之就要检查26芯边线的插头与插座之间是否接触良好，8.2Ω电阻是 否断路。 Micro-Computer Controller 微机控制器 Step-Motor is out of step. 步进电机失步 Firstly implement the self-inspection to the Controller. The specific methods are as follows: Shut off “Machine Tool Controller”, and “24V Mains Switch”, pull out “25-Core Plug” which connects “24V Power Supply” with the “Controller”, turn on “Controller Mains Switch”, input one “Bias Program”, put “Automatic / Analog Switch Lamp” into “Analog Condition”, then carry out this “Program Regulative Operating Point Rotary Button X, Y (only available in U, V Taper Machine), three “Indicating Lamps” should skip respectively in turn. If it is dark or constantly bright to one Lamp, it shows that there is some trouble in “Machine Tool Controller Output”. It commonly only needs to remove certain “Power Amplification Tube” in solve the problem in the “Controller”. Or it is caused by bad contact in the “Internal Connector” of the Controller. Open the Controller Cover Plate, simulate one “Bias Program”, by this time detect that how many volt fluctuation should have for every “Power Amplification Tube Input Terminal”. If it has normal 50 condition to every tube, then it should check whether it has about 10V Voltage Fluctuation or not in every “Power Amplification Tube Input Terminal”. It should remove the defect “Power Amplification Tube” in time. If there is only one abnormal input from “Power Amplification Tube”, it should check whether it has sound contact to “8-Core Connector” or not. Please immediately send the bad-contact one to the factory for repair. 首先要对控制器进行自检，具体方法是:关掉单板机及24伏电源开关，拔下24伏电源与控 制器连接的25芯插头，打开控制器电源开关，输入1道斜线程序，把自动/模拟开关打在模 拟状态，然后执行这道程序调节工作点旋钮X、Y(U、V锥度机才有)各三个指示灯应轮 回跳动，如发现有一只灯不亮或长亮则说明单板机输出有故障，控制器故障一般只需要换某 只功放管，也可能控制器内部接插件接触不良造成。打开控制器盖板、模拟走1道斜线程序， 此时检测每个功放管输入端应有几伏电压波动，如果每个管子都正常则应检查每个功放管输 入端是否有10伏左右的电压波动。哪个管子输入不正常，就得更换此功放管，如果功放管 有一个输入不正常，应检查8芯接插件是否接触良好，如果接触不良，请送交厂方维修。 No High Frequency Output 没有高频输出 Whether “HF Indicating Lamp” is bright or not. If it is bright, then it should test whether or not it is “,12V” to the “Controller 25-Core Jack 10-Foot Voltage”. If it is not, check whether or not it damages “HF on-off Relay” in the “Controller Power Board”. If it is so, please renew it in time. 高频指示灯是否点亮，如果点亮，则需测控制器25芯插口10脚电压是否是负12伏，如果 没有，检查控制器电源板上的高频通断继电器是否损坏，如损坏需更换。 Page 30 第30页 Chapter Three 第三章 Safety Protection Measures of Machine Tool Running System 机床电器安全保护措施 There is “Strong Current Warning Mark” in “Machine Tool Running System Control Box Door” to remind the consumers of the safety matters. 机床电器控制箱门上有强电警示标志以提醒用户注意安全。 There are “Insulation Bushing” to the “Terminals, Components and Parts with Strong Current”. It uses belts to bind the Conductors which are not in the “Wire Groove”. As a result, it gets the tidy and secure wiring.. 带有强电的元器件及接线端都有绝缘套管，对不在线槽中的导线均用扎带扎住，从而使布线 整齐又安全。 Machine Tool Running System has been installed with Mushroom Emergency Stop Switch. 51 When emergent condition occurs, it can press “Emergency Stop Switch” to immediately stop the Machine Tool. 机床电器装有蘑菇急停开关，遇到紧急情况，可按急停开关停机。 Kinetic Wire Motor has been installed with Power-off, Brake Devices. The Wire Tube can make prompt brake when Power-Interruption occurs during working process for purpose of prevent “Wire-Coiling Tube” from rushing out of its original place. 运丝电机装有断电、刹车装置，工作中遇断电，丝筒可迅速刹车，以防止卷丝筒冲出。 The Machine Tool has broken wire protection measures. The Machine Tool can immediately disconnect with Power Source upon Broken Wires. 机床有断丝保护措施，遇断丝，机床可立即断电。 Page 31 第31页 24V Drive Mains Schematic Diagram 24伏驱动电源原理图 Page 33 第33页 Machine Tool Running System Schematic Diagram (?) 机床电器原理图(三) Page 28 第38页 Machine Tool Controller 25-Core (Five-Phase Ten-Beat) Interface 单板机25芯(五相十拍)接口 Machine Stop 停机 HF Switch 高频开关 Sampling 取样 Computer Communication Interface 电脑通讯接口 26-Core Aviation Socket Interface (Five-Phase Ten-Beat) 52 26芯航空插座接口(五相十拍) Machine Stop 停机 Sampling 取样 High Frequency 高频 HF Control 高频控制 Positive 12, Negative 15 正12、负15 Positive 11, Negative 16 正11、负16 26-Core Aviation Socket Interface (Three-Phase Six-Beat) 26芯航空插座接口(三相六拍) Machine Stop 停机 Sampling 取样 High Freqency 高频 HF Control 高频控制 Positive 12, Negative 15 正12、负15 Positive 11, Negative 16 正11、负16 53