中英文DK77系列數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系列數控電火花線切割機床Use Description使用說明書Ningbo Zhongyuan Machine Tool Co., Ltd.寧波中原機床有限公司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工作原理及結構Principle of Operation工作原理Mechanical System Structure機械系統(tǒng)

2、結構Technical Parameters技術參數Characteristic Model Stipulations特性型號的規(guī)定Basic Parameters基本參數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機床調整與操作Preparation Works準備工作Coil Holder Adjustment線架調整Workt

3、able Regulation工作臺調整Kinetic Wire Component Adjustment and Electrode Wire Coiling 運絲部件調整及電極絲繞裝Guide Wheel Adjustment導輪的調整Work-Piece Clamping工件裝夾Operation and Points for Attention操作及注意事項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 of

4、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 機床電器安裝及使用說明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：原因及排除Safety Protection Measures of

5、Machine Tool Running System 機床電器安全保護措施Schematic Drawing of 25V Drive Head Mains25伏驅頭電源原理圖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 s

6、erial 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,

7、uneasily-clamped thin wall spares etc. If the Machine Tool gets the aid of the auxiliary extra-large specification of uTaper 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 ter

8、rify 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.本系列產品最大特點是對被加工的金屬材

9、料性質無特殊要求，原則上凡導電材料均可加工。 如超硬、硬質合金、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。隨著高科技產品不斷出現(xiàn)，國民 經濟的不斷繁榮，我們預言，本系列產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

10、。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 O

11、peration 工作原理及結構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 uMolybdenum Wire or Hard Brass

12、 Wire as the “Tool Electrode . Under the “High Frequency Pulse Voltage Functions0 , 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 i

13、n 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-Comp

14、uter Control.本系列產品是應用“放電加工”機理，輔以自動控制及微機相結合的機電一體化產品。機床 通常采用鋁絲或硬性黃銅紋作為工具電極，在高頻脈沖電壓作用下，利用液體介質被擊穿后 形成火花放電，在火花通道中瞬間產生大量的熱能，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 Amplifica

15、tion功放Micro-Computer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 uComputer System, , uMachine Tool Control Syst

16、em , 44Mechanical System” . The Processing Documents“ form Computer-1nput Machine Tool Control System through programming. The uControl System controls the uMachine Tool to complete the program actions and therefore finishes the Processing Instructions. The 44Mechanical System is based upon the uMac

17、hine Tool Body” . It includes the Coordinates Work-Table , Kinetic Wire System , uCooling 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，包括坐標工作臺、運絲系統(tǒng)、冷卻系統(tǒng)。The Micro-Computer SystemM allocated by this Machine Tool is a new generation aControl Sys

18、tem . 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 , uInterface CircuitM , “Stepping Drive CircuitM . It has the sound operationality because of t

19、he adoption of the advanced 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、電器部分兀其主要由微機 配上專用的插補控制軟件及接口電路和步進驅動電路組成，由于采用了先進的CNC技術，所 以具有良好的操作性。Mechanical System Structure 機械系統(tǒng)結構The Mechanical System Part of this uMachine Tool M is composed of the key elements such as the Machine Tool Body，44 Work-Table M , “

20、Kinetic Wire Device M , “Coil 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)及冷卻系統(tǒng)等重 要部件組成。Machine Tool Body 床身uMachine Tool BodyM is a basic part of the uMachine Toolv . If all these components have been installed in the body, it can guarantee the high accurac

21、y 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 uMachine Tool” . It can remove the H

22、oisting Screws after installation. The large-size Machine Tools use the Hoisting Holes . The aSupporting FeetM with the adjustable level have been installed in the bottom ofthe uMachine Tool Body” .床身是機床的基礎件。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。本公司生產的DK7750以下機床，其床身前、后兩而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

23、可拆下，大型機床用起吊孔，床身底部裝有可供調 節(jié)水平的支承腳。Work-Table工作臺The Worktable is composed of two uUpper and Lower Tool CarriagesM making relative cross movements and precise uLead-Screw Drive Pair M . Please refer to Table 2 and 3 for the 44 Drive SystemM .工作臺是由二塊相對十字運動的上下拖板及精密絲杠傳動副所組成，其傳動系統(tǒng)見圖2和圖 3。The Structural Formu

24、la of V-Thread Drive” is as follows: (See Table 2) 三角螺紋傳動的結構式如下(見圖2)X-Directional ： Feed Pulse Step-Motor El Gear Pair Zi/Z：-* Lead-Screw M：X向：進給脈沖一步進電機及一齒輪副Z/ZL絲杠副扎Y-Directional ： Feed Pulse Step-Motor El Gear Pair Zo/Zl Lead-Screw Pair MeY向：進給脈沖一步進電機艮一齒輪副乙/Zl絲杠副也The Structural Formula of Ball-Scre

25、w Drive Pair is as follows: See Table 3滾珠絲杠傳動副的結構式如下，見圖3：X-Directional ： Feed Pulse -* Step-Motor E：-* Gear Pair Zx/Z：Lead-Screw Pair G：X向：進給脈沖一步進電機E：齒輪副Z/Z二一絲杠副G,Y-Directional ： Feed Pulse Step-Motor El Gear Pair Z/Zl Lead-Screw Pair Go Y向：進給脈沖一步進電機艮一齒輪副Zo/Zl絲杠副G：In addition, it can also fulfill th

26、e quick movement of the Work-Table“ through X-Directional and Y-Directional HandlesM .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3

27、Ball-Screw and Synchronous Belt Drive System滾珠絲杠及同步帶傳動系統(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 uStroke Switch

28、, 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.由電機、聯(lián)軸器、貯絲筒、齒輪傳動部件、滑板、動絲底座及絲杠副等組成。由于左右撞塊 及行程開關的作用，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：Mo

29、tor H-* Coupler High Speed Rotating Wire Tube Gear Z/Zs Z：/Z3 f Lead-Screw Pair T電機H-聯(lián)軸器一高速旋轉絲筒一齒輪Z5/Z6 Z：/Zl絲杠副ToCoil Holder線架“Coil holder is a device which supports the uElectrode Wire” , adjusts the Cutting Thickness and carries out various uTaper CuttingM . It installs the “Electrode Wire onto W

30、ork-Piece” which has been chucked in the uWork-TableM through “Wire-Positioning Wheel” , uConductive Device , uGuide-Wheel Group.uConductive Block” electrifies Electrode Wire” under action of “HF Pulse Mains . The Liquid Medium ejected from “Liquid Injection Device* has been broken down to form u Sp

31、ark Discharge” which completes the Work-Piece Cutting. 線架是用來支承電極絲，調節(jié)切割厚度及進行各種錐度切割的一個裝置。它通過排絲輪，導 電裝置及導輪組，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被擊穿后形成火花放電來完成對工 件的切割。Because it acts to various uStructural Composition of the “Coil Holder , it is divided into Fixed Coil HolderM aAdjus

32、table Coil Holder , aTaper Coil HolderM .由于作用不同線架的結構形成，通常有固定線架，可調線架及錐度線架之區(qū)別。Fixed Coil Holder固定線架The uUpper and Lower Coil HoldersM 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 Stabi

33、lity. 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 Holdersn .此種結構線架其上下懸臂固定于立柱之上，不可調行。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范圍較小，且不能調|葭因此產品加工有局限性。目前已

34、逐步被可 調形線架所代替。Elevated Adjustable Coil Holder升降式可調線架The uupper coil Holder can move up and down along the uUpright 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

35、one u Taper Cutting Device. The uTaper Device produced by our company has the multiple specifications such as 6 , 12 , 150 , 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 F

36、our-Shaft LinkageM .這種結構實際上是升降式再加上一個錐度切割裝置，本公司生產的錐度裝置有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技術參數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 Model E, Model F, Model G

37、according to different uPower Stroke (Specification) and Structural Form of the Coil Holder.我公司目前生產的DK77系列產品，主要是按其工作行程(規(guī)格)及其線架結構形式不同可 分為E型、F型和G型三種。Model E - Adjustable Coil Holder Height, therefore it is called uAdjustable Coil HolderM .E型一一線架高度可調節(jié)，稱可調線架。Model FThe “Coil Holder HeightM can be regula

38、ted, it is also allocated withbelow 6“ Taper Cutting Device. Therefore it is called Adjustable Small-Taper Coil Holder” .F型一一線架高度可調節(jié)且配以6以下錐度切割裝置，稱可調小錐度線架。Model GThe “Coil Holder Height ” can be regulated. It is also allocated withour patent Large-Taper Cutting Device with the uTracking Hydrojet . It

39、 is called Large Taper Coil Holder . It commonly has 30 or 60 Upper Limit Specifications and so on.G型一一線架高度可調門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 JB/T7445 and 2-94.型號組成及代表意義依據標準JB/T7445、2-94o Coil Holder Form 線架形

40、式Principal Parameter (Work-Table Lateral Stroke 1/10) 主參數(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 技術參數 Unit： mm 單位：mm Model 型號 Parameter 參數 Power Stroke 工作行程 Max. Length of Machining

41、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電極絲電流范圍Operating Mains工作電源Max. Machining Current 最大

42、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)、步進電機驅動 Description: 說明：The above uCutting Taper“ and Operating ThicknessM take 150mm as the Calculation Height”.以上切割錐度、工作厚度以150mm為計算高度；Surface Roughness

43、Ra2 5m has been determined when uCutting Speed is 20mm/min. 表面粗度RaW2. 5m,是在切割速度為20mm:/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 outer packing

44、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 sc

45、rew 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 suc

46、h 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，以免損傷外觀。搬運中應避免顛簸、傾 斜、撞擊等不平穩(wěn)現(xiàn)象。Machine Tool Installation 機床安裝It should keep a clean, dust-f

47、ree installation environment without vibrating source; corrosive gas and large wattage electrical equipment interference. It better controls 205 to the operating environment temperature.安裝環(huán)境應清潔，無粉塵、無振動源，無腐蝕氣體，無大功率電氣設備干擾。建議工作環(huán)境 溫度最好控制在205C。As far as the aInstallation Direction of the Machine Tool“ is

48、 concerned, it is better for the operator to face the uNatural 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 , “G

49、uide Rail” , u 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 uMachine Tool Body , it should not exceed 0. 04/1000 requirements for the lateral and longitudinal directions of the uLev

50、el GaugeM in the uWork-TableM . The Machine Tool should have the reliable connection with the uProtective Ground System for purpose of ensuring the safe use.機床安裝方向盡量使操作者而對自然光源。機床初步安放后，應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。借助床身下面的調整螺釘，使水平儀在工作分縱橫二個方向均不得超 過0.04/1000的要求。機床應與

51、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 to correctly co

52、nnect the Sockets with various Plugs.聯(lián)機前應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，讓機床空載運行，觀察其工作狀態(tài)是否正常。The contents include the following： 內容有：The Control Cabinetv should h

53、ave 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 u Mot ion Pair in the Machine Tool.機床各部分運動副工作正常：No Error in uPulse 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 various uStro

54、ke Switch Contacts.各個行程開關觸點動作靈敏；Smooth flow of the uWorking Solution in various uInlet and Outlet Pipes” with normal pressure, the MWorking Solution should wrap Molybdenum Wire. 工作液各進出管暢通無阻，壓力正常，工作液裹住鋁絲。Fill the Lubricant according to the lubricating demands of the Machine Tool. 按機床潤滑要求注油；See Diagra

55、m 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. T

56、he 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重要，因此務必請用戶重視。Diagram 5圖5Machine Tool Main Frame Hoisting Diagram 機床主機吊運圖Page 8第8頁K-DirectionalK向Diagram 6圖6The Conceptual Diagram to various “Kinetic Part Lubricating Positions of the Work-Table

57、工作臺各運動件潤滑部件示意圖Diagram 7圖7Lubricant Oil of “Kinetic Wire Component 運絲部件潤滑油Table 2表2No.編號Lubricating Positions 潤滑部位LubricatingMode 潤滑方式Oil 油類Adding Time 加油期Points for Attention 注意事項Table 6 圖6 A、BLead-Screw 絲杠Oil Gun 油槍30# Lubricant 30#機油Once aWeek 每周一次During the oil adding time, please shake the “Hand WheelM at the same time so that the Lead-Screw can make the round-