A real-time calibration control system of a high-frequency spark machine

Abstract

The application provides a real-time calibration control system of a high-frequency spark machine, and relates to the field of electric digital data processing.The system comprises an interactive processing module, an analysis control module, a state monitoring module and a calibration control module.The interactive processing module is used for inputting a processing file and displaying processing content.The analysis control module is used for analyzing the processing file and outputting basic control information.The state monitoring module is used for monitoring the state of a workpiece in a processing process.The calibration control module controls processing parameters based on the basic control information and the state of the workpiece.When the system processes the workpiece, the processing parameters can be calibrated and adjusted in real time according to the processing state, so that a high-precision processing effect is obtained.

Description

Technical Field

[0001] This invention relates to the field of electronic digital data processing, and more specifically to a real-time calibration and control system for a high-frequency EDM machine. Background Technology

[0002] High-frequency EDM is a non-traditional processing method that uses the heat energy generated by electric sparks to process materials. The working principle of high-frequency EDM is based on the phenomenon of electric spark discharge. During the discharge process, a series of rapid and continuous electric sparks are generated between two electrodes. These electric sparks generate high temperatures in a tiny area, which are sufficient to melt or evaporate the material. By precisely controlling the distance between the electrodes and the electric discharge parameters, precise removal of workpiece material can be achieved. However, existing EDM control systems usually maintain the same parameters during the processing, resulting in a certain gap between the processing effect and the expected effect. The processing effect still needs to be improved.

[0003] The foregoing description of the background art is intended only to facilitate understanding of the invention. This description does not endorse or acknowledge any common general knowledge in the materials mentioned.

[0004] Many EDM control systems have been developed. Extensive research and reference have revealed existing control systems, such as the one disclosed in publication number CN111779608B. These systems generally include: a low-voltage on-board power supply, a control module, a high-frequency discharge module, a high-energy replenishment module, and spark plugs. The low-voltage on-board power supply provides power to the entire system. The control module includes the logical allocation of control signals from the high-frequency discharge control module and the high-energy replenishment module to achieve precise control of the discharge frequency and duration. The high-frequency discharge module includes a first capacitor, a second capacitor, and a high-voltage coil, used to provide high-frequency breakdown voltage. The first input terminal of the high-voltage coil is connected to the discharge ignition output terminal of the first capacitor, the first output terminal of the high-voltage coil is connected to ground, the second input terminal of the high-voltage coil is connected to the output terminal of the high-voltage coil, and the second output terminal of the high-voltage coil is connected to the spark plugs and the high-energy replenishment module. However, this system uses the same parameters to process the workpiece, and there is still room for improvement in the processing effect. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings by proposing a real-time calibration and control system for a high-frequency EDM machine.

[0006] The present invention adopts the following technical solution:

[0007] A real-time calibration and control system for a high-frequency EDM machine includes an interactive processing module, a parsing control module, a status monitoring module, and a calibration control module.

[0008] The interactive processing module is used to input the processing file and display the processing content; the parsing control module is used to parse the processing file and output basic control information; the status monitoring module is used to monitor the workpiece status during the processing; and the calibration control module controls the processing parameters based on the basic control information and the workpiece status.

[0009] The interactive processing module includes an information input unit and an information display unit. The information input unit is used to input processing files, and the information display unit is used to display finished product images and real-time processing images in the processing files.

[0010] The analysis control module includes a positioning analysis unit and an intensity analysis unit. The positioning analysis unit divides the processing process into multiple positioning areas according to the processing file. Each positioning area includes one or more cyclically executed movement control commands. Adjacent positioning areas are changed using a single-execution movement control command. The intensity analysis unit sets a processing intensity for each positioning area according to the processing file.

[0011] The status monitoring module includes a visual monitoring unit and an information transmission unit. The visual monitoring unit is used to monitor the surface processing of the workpiece, and the information transmission unit is used to transmit the monitored information to the calibration control module and the interactive processing module.

[0012] The calibration control module includes a motion control unit, an electrical control unit, and a distance control unit. The motion control unit is used to control the movement of the electrode, the current control unit is used to control the electrical parameters in the electrode, and the distance control unit is used to control the distance between the electrode and the workpiece.

[0013] Furthermore, the strength analysis unit includes a material parameter register, a precision parameter register, and a strength calculation processor. The material parameter register is used to store parameters of different workpiece materials, the precision parameter register is used to store parameters of different precision requirements, and the strength calculation processor is used to calculate the basic strength of the entire workpiece processing.

[0014] The strength calculation processor retrieves the corresponding parameters from the material parameter register and the precision parameter register according to the material and precision requirements in the processing file, and calculates the basic strength Str according to the following formula:

[0015]

[0016] Where pm is the material parameter, pa is the precision parameter, λ1 is the first strength coefficient, and λ2 is the second strength coefficient;

[0017] Furthermore, the system's control process for machining the workpiece includes the following steps:

[0018] S1. The calibration control module receives the positioning information and intensity information from the analysis control module;

[0019] S2. The motion control unit obtains the cyclic movement command from the positioning information and calculates the movement speed based on the intensity information, and executes the planar movement of the electrode. The electrical control unit calculates the voltage and voltage change frequency of the electrode based on the intensity information and executes the energization of the electrode. The distance control unit calculates the distance between the electrode and the workpiece based on the intensity information and executes the vertical movement of the electrode.

[0020] S3. The calibration control module receives monitoring information from the status monitoring module;

[0021] The mobile control unit in S4 calibrates the movement speed based on the monitoring information, the electrical control unit calibrates the electrical data based on the monitoring information, and the distance control unit calibrates the distance data based on the monitoring information.

[0022] S5. After the visual monitoring unit detects that a positioning area has been processed, it stops the power supply to the electrode and restores the initial vertical distance of the electrode.

[0023] S6. The motion control unit obtains a change motion command from the positioning information and moves the electrode to a new positioning area;

[0024] S7. Repeat steps S2 to S6 until processing in all positioning areas is completed;

[0025] Furthermore, the electrical control unit includes a basic electrical calculation processor, a calibration electrical calculation processor, and a power-on control processor. The basic electrical calculation processor is used to calculate the power-on data of the electrode in step S2, the calibration electrical calculation processor is used to calculate the power-on data of the electrode in step S4, and the power-on control processor is used to control the power-on status of the electrode.

[0026] Furthermore, the distance control unit includes a basic distance calculation processor, a calibration distance calculation processor, and a distance control processor. The basic distance calculation processor is used to calculate the distance value of the electrode in step S2, the calibration distance calculation processor is used to calculate the distance value of the electrode in step S4, and the distance control processor is used to control the distance between the electrode and the workpiece.

[0027] The beneficial effects achieved by this invention are:

[0028] This system first calculates the basic strength of each processing area, determines the initial processing parameters based on the basic strength, and collects the processing status in real time as the processing progresses. Then, it calibrates and adjusts the processing parameters in real time based on the processing status, so that the processing effect can better meet the accuracy requirements and reduce the occurrence of defects during the processing.

[0029] To further understand the features and technical content of the present invention, please refer to the following detailed description and drawings of the present invention. However, the drawings provided are for reference and illustration only and are not intended to limit the present invention. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall structural framework of the present invention;

[0031] Figure 2 This is a schematic diagram of the strength analysis unit structure of the present invention;

[0032] Figure 3 This is a schematic diagram of the mobile control unit structure of the present invention;

[0033] Figure 4 This is a schematic diagram of the electrical control unit structure of the present invention;

[0034] Figure 5 This is a schematic diagram of the distance control unit of the present invention. Detailed Implementation

[0035] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the spirit of the present invention. Furthermore, the accompanying drawings of the present invention are for simple illustrative purposes only and are not depictions of actual dimensions; this is stated beforehand. The following embodiments will further describe the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention.

[0036] Example 1.

[0037] This embodiment provides a real-time calibration and control system for a high-frequency EDM machine, combined with... Figure 1 It includes an interactive processing module, a parsing control module, a status monitoring module, and a calibration control module;

[0038] The interactive processing module is used to input the processing file and display the processing content; the parsing control module is used to parse the processing file and output basic control information; the status monitoring module is used to monitor the workpiece status during the processing; and the calibration control module controls the processing parameters based on the basic control information and the workpiece status.

[0039] The interactive processing module includes an information input unit and an information display unit. The information input unit is used to input processing files, and the information display unit is used to display finished product images and real-time processing images in the processing files.

[0040] The analysis control module includes a positioning analysis unit and an intensity analysis unit. The positioning analysis unit divides the processing process into multiple positioning areas according to the processing file. Each positioning area includes one or more cyclically executed movement control commands. Adjacent positioning areas are changed using a single-execution movement control command. The intensity analysis unit sets a processing intensity for each positioning area according to the processing file.

[0041] The status monitoring module includes a visual monitoring unit and an information transmission unit. The visual monitoring unit is used to monitor the surface processing of the workpiece, and the information transmission unit is used to transmit the monitored information to the calibration control module and the interactive processing module.

[0042] The calibration control module includes a motion control unit, an electrical control unit, and a distance control unit. The motion control unit is used to control the movement of the electrode, the current control unit is used to control the electrical parameters in the electrode, and the distance control unit is used to control the distance between the electrode and the workpiece.

[0043] The strength analysis unit includes a material parameter register, a precision parameter register, and a strength calculation processor. The material parameter register is used to store parameters of different workpiece materials, the precision parameter register is used to store parameters of different precision requirements, and the strength calculation processor is used to calculate the basic strength of the entire workpiece processing.

[0044] The strength calculation processor retrieves the corresponding parameters from the material parameter register and the precision parameter register according to the material and precision requirements in the processing file, and calculates the basic strength Str according to the following formula:

[0045]

[0046] Where pm is the material parameter, pa is the precision parameter, λ1 is the first strength coefficient, and λ2 is the second strength coefficient;

[0047] The system's control process for machining the workpiece includes the following steps:

[0048] S1. The calibration control module receives the positioning information and intensity information from the analysis control module;

[0049] S2. The motion control unit obtains the cyclic movement command from the positioning information and calculates the movement speed based on the intensity information, and executes the planar movement of the electrode. The electrical control unit calculates the voltage and voltage change frequency of the electrode based on the intensity information and executes the energization of the electrode. The distance control unit calculates the distance between the electrode and the workpiece based on the intensity information and executes the vertical movement of the electrode.

[0050] S3. The calibration control module receives monitoring information from the status monitoring module;

[0051] The mobile control unit in S4 calibrates the movement speed based on the monitoring information, the electrical control unit calibrates the electrical data based on the monitoring information, and the distance control unit calibrates the distance data based on the monitoring information.

[0052] S5. After the visual monitoring unit detects that a positioning area has been processed, it stops the power supply to the electrode and restores the initial vertical distance of the electrode.

[0053] S6. The motion control unit obtains a change motion command from the positioning information and moves the electrode to a new positioning area;

[0054] S7. Repeat steps S2 to S6 until processing in all positioning areas is completed;

[0055] The electrical control unit includes a basic electrical calculation processor, a calibration electrical calculation processor, and a power-on control processor. The basic electrical calculation processor is used to calculate the power-on data of the electrode in step S2, the calibration electrical calculation processor is used to calculate the power-on data of the electrode in step S4, and the power-on control processor is used to control the power-on status of the electrode.

[0056] The distance control unit includes a basic distance calculation processor, a calibration distance calculation processor, and a distance control processor. The basic distance calculation processor is used to calculate the distance value of the electrode in step S2, the calibration distance calculation processor is used to calculate the distance value of the electrode in step S4, and the distance control processor is used to control the distance between the electrode and the workpiece.

[0057] Example 2.

[0058] This embodiment includes all the contents of Embodiment 1, and provides a real-time calibration control system for a high-frequency EDM machine, including an interactive processing module, a parsing control module, a status monitoring module and a calibration control module;

[0059] The interactive processing module is used to input the processing file and display the processing content; the parsing control module is used to parse the processing file and output basic control information; the status monitoring module is used to monitor the workpiece status during the processing; and the calibration control module controls the processing parameters based on the basic control information and the workpiece status.

[0060] The interactive processing module includes an information input unit and an information display unit. The information input unit is used to input processing files, and the information display unit is used to display finished product images and real-time processing images in the processing files.

[0061] The analysis control module includes a positioning analysis unit and an intensity analysis unit. The positioning analysis unit divides the processing process into multiple positioning areas according to the processing file. Each positioning area includes one or more cyclically executed movement control commands. Adjacent positioning areas are changed using a single-execution movement control command. The intensity analysis unit sets a processing intensity for each positioning area according to the processing file.

[0062] The status monitoring module includes a visual monitoring unit and an information transmission unit. The visual monitoring unit is used to monitor the surface processing of the workpiece, and the information transmission unit is used to transmit the monitored information to the calibration control module and the interactive processing module.

[0063] The calibration control module includes a motion control unit, an electrical control unit, and a distance control unit. The motion control unit is used to control the movement of the electrode, the current control unit is used to control the electrical parameters in the electrode, and the distance control unit is used to control the distance between the electrode and the workpiece.

[0064] The system's control process for machining the workpiece includes the following steps:

[0065] S1. The calibration control module receives the positioning information and intensity information from the analysis control module;

[0066] S2. The motion control unit obtains the cyclic movement command from the positioning information and calculates the movement speed based on the intensity information, and executes the planar movement of the electrode. The electrical control unit calculates the voltage and voltage change frequency of the electrode based on the intensity information and executes the energization of the electrode. The distance control unit calculates the distance between the electrode and the workpiece based on the intensity information and executes the vertical movement of the electrode.

[0067] S3. The calibration control module receives monitoring information from the status monitoring module;

[0068] The mobile control unit in S4 calibrates the movement speed based on the monitoring information, the electrical control unit calibrates the electrical data based on the monitoring information, and the distance control unit calibrates the distance data based on the monitoring information.

[0069] S5. After the visual monitoring unit detects that a positioning area has been processed, it stops the power supply to the electrode and restores the initial vertical distance of the electrode.

[0070] S6. The motion control unit obtains a change motion command from the positioning information and moves the electrode to a new positioning area;

[0071] S7. Repeat steps S2 to S6 until processing in all positioning areas is completed;

[0072] Combination Figure 2 The strength analysis unit includes a material parameter register, a precision parameter register, and a strength calculation processor. The material parameter register is used to store parameters of different workpiece materials, the precision parameter register is used to store parameters of different precision requirements, and the strength calculation processor is used to calculate the basic strength of the entire workpiece processing.

[0073] The strength calculation processor retrieves the corresponding parameters from the material parameter register and the precision parameter register according to the material and precision requirements in the processing file, and calculates the basic strength Str according to the following formula:

[0074]

[0075] Where pm is the material parameter, pa is the precision parameter, λ1 is the first strength coefficient, and λ2 is the second strength coefficient;

[0076] Combination Figure 3 The motion control unit includes a basic motion calculation processor, a calibration motion calculation processor, and a motion execution processor. The basic motion calculation processor is used to calculate the moving speed of the electrode in step S2, the calibration motion calculation processor is used to calculate the moving speed of the electrode in step S4, and the motion execution processor is used to execute the planar movement of the electrode.

[0077] Combination Figure 4 The electrical control unit includes a basic electrical calculation processor, a calibration electrical calculation processor, and a power-on control processor. The basic electrical calculation processor is used to calculate the power-on data of the electrode in step S2, the calibration electrical calculation processor is used to calculate the power-on data of the electrode in step S4, and the power-on control processor is used to control the power-on status of the electrode.

[0078] Combination Figure 5The distance control unit includes a basic distance calculation processor, a calibration distance calculation processor, and a distance control processor. The basic distance calculation processor is used to calculate the distance value of the electrode in step S2, the calibration distance calculation processor is used to calculate the distance value of the electrode in step S4, and the distance control processor is used to control the distance between the electrode and the workpiece.

[0079] The basic mobile computing processor calculates the moving speed v of the electrode according to the following formula:

[0080]

[0081] Among them, v max For the maximum moving speed of the electrode, [Str min Str max [This refers to the strength range of the workpiece;]

[0082] The basic electrical computing processor calculates the voltage U and frequency f of the electrodes according to the following formula:

[0083]

[0084]

[0085] Among them, U max f is the maximum voltage applied to the electrode. max λ3 is the maximum frequency at which the electrode is energized, λ4 is the voltage adjustment coefficient, and λ5 is the frequency adjustment coefficient.

[0086] The basic distance calculation processor calculates the distance d between the electrode and the workpiece according to the following formula:

[0087]

[0088] Among them, [d min d max [This refers to the effective distance range between the electrode and the workpiece;]

[0089] The visual monitoring unit includes an image capturing processor, a width monitoring processor, and a depth monitoring processor. The image capturing processor is used to capture real-time processing images of the workpiece. The width monitoring processor obtains the real-time width w based on the captured images. The depth monitoring processor obtains the real-time depth h based on the captured images.

[0090] The calibration motion calculation processor calculates the calibrated movement speed v′ according to the following formula:

[0091]

[0092] Where w0 is the required width and h0 is the required depth;

[0093] The calibration electrical calculation processor calculates the calibrated voltage U′ and frequency f′ according to the following formula:

[0094]

[0095]

[0096] The calibration distance calculation processor calculates the calibrated distance value d′ according to the following formula:

[0097]

[0098] The content disclosed above is only a preferred and feasible embodiment of the present invention, and is not intended to limit the scope of protection of the present invention. Therefore, all equivalent technical changes made based on the content of the present invention specification and drawings are included within the scope of protection of the present invention. Furthermore, the elements therein can be updated as technology develops.

Claims

1. A real-time calibration control system for a high frequency spark machine, characterized in that, It includes an interactive processing module, a parsing control module, a status monitoring module, and a calibration control module; The interactive processing module is used to input the processing file and display the processing content; the parsing control module is used to parse the processing file and output basic control information; the status monitoring module is used to monitor the workpiece status during the processing; and the calibration control module controls the processing parameters based on the basic control information and the workpiece status. The interactive processing module includes an information input unit and an information display unit. The information input unit is used to input processing files, and the information display unit is used to display finished product images and real-time processing images in the processing files. The analysis control module includes a positioning analysis unit and an intensity analysis unit. The positioning analysis unit divides the processing process into multiple positioning areas according to the processing file. Each positioning area includes one or more cyclically executed movement control commands. Adjacent positioning areas are changed using a single-execution movement control command. The intensity analysis unit sets a processing intensity for each positioning area according to the processing file. The status monitoring module includes a visual monitoring unit and an information transmission unit. The visual monitoring unit is used to monitor the surface processing of the workpiece, and the information transmission unit is used to transmit the monitored information to the calibration control module and the interactive processing module. The calibration control module includes a motion control unit, an electrical control unit, and a distance control unit. The motion control unit is used to control the movement of the electrode, the electrical control unit is used to control the electrical parameters in the electrode, and the distance control unit is used to control the distance between the electrode and the workpiece. The system's control process for machining the workpiece includes the following steps: S1. The calibration control module receives the positioning information and intensity information from the analysis control module; S2. The motion control unit obtains the cyclic movement command from the positioning information and calculates the movement speed based on the intensity information, and executes the planar movement of the electrode. The electrical control unit calculates the voltage and voltage change frequency of the electrode based on the intensity information and executes the energization of the electrode. The distance control unit calculates the distance between the electrode and the workpiece based on the intensity information and executes the vertical movement of the electrode. S3. The calibration control module receives monitoring information from the status monitoring module; S4. The motion control unit calibrates the movement speed based on the monitoring information, the electrical control unit calibrates the electrical data based on the monitoring information, and the distance control unit calibrates the distance data based on the monitoring information. S5. After the visual monitoring unit detects that a positioning area has been processed, it stops the power supply to the electrode and restores the initial vertical distance of the electrode. S6. The motion control unit obtains a change motion command from the positioning information and moves the electrode to a new positioning area; S7. Repeat steps S2 to S6 until processing in all positioning areas is completed; The strength analysis unit includes a material parameter register, a precision parameter register, and a strength calculation processor. The material parameter register is used to store parameters of different workpiece materials, the precision parameter register is used to store parameters of different precision requirements, and the strength calculation processor is used to calculate the basic strength of the entire workpiece processing. The strength calculation processor retrieves the corresponding parameters from the material parameter register and the precision parameter register according to the material and precision requirements in the processing file, and calculates the basic strength Str according to the following formula: ； Wherein, pm is material parameter, pa is precision parameter, is the first intensity coefficient, is the second intensity coefficient; The motion control unit includes a basic motion calculation processor, a calibration motion calculation processor, and a motion execution processor. The basic motion calculation processor is used to calculate the moving speed of the electrode in step S2, the calibration motion calculation processor is used to calculate the moving speed of the electrode in step S4, and the motion execution processor is used to execute the planar movement of the electrode. The electrical control unit includes a basic electrical calculation processor, a calibration electrical calculation processor, and a power-on control processor. The basic electrical calculation processor is used to calculate the power-on data of the electrode in step S2, the calibration electrical calculation processor is used to calculate the power-on data of the electrode in step S4, and the power-on control processor is used to control the power-on status of the electrode. The distance control unit includes a basic distance calculation processor, a calibration distance calculation processor, and a distance control processor. The basic distance calculation processor is used to calculate the distance value of the electrode in step S2, the calibration distance calculation processor is used to calculate the distance value of the electrode in step S4, and the distance control processor is used to control the distance between the electrode and the workpiece. The basic mobile computing processor calculates the moving speed v of the electrode according to the following formula: ； Among them, v max For the maximum moving speed of the electrode, [Str min Str max [This refers to the strength range of the workpiece;] The basic electrical computing processor calculates the voltage U and frequency f of the electrodes according to the following formula: ； ； Among them, U max f is the maximum voltage applied to the electrode. max The maximum frequency at which the electrodes are energized. This is the voltage regulation coefficient. This is the frequency adjustment coefficient; The basic distance calculation processor calculates the distance d between the electrode and the workpiece according to the following formula: ； wherein [d min , d max ] is the effective distance interval between the electrode and the workpiece; The visual monitoring unit includes an image capturing processor, a width monitoring processor, and a depth monitoring processor. The image capturing processor is used to capture real-time processing images of the workpiece. The width monitoring processor obtains the real-time width w based on the captured images. The depth monitoring processor obtains the real-time depth h based on the captured images. The calibrated mobile speed is calculated by the calibration mobile computing processor according to the following equation : ； Where w0 is the required width and h0 is the required depth; The calibrated electrical computing processor calculates the calibrated voltage according to the following equation and frequency : ； ； The calibration distance calculation processor calculates the calibrated distance value according to the following equation : 。

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