Data processing method and device for synchronous interpolation of upper and lower special-shaped planes generated by full-digital linear cutting numerical control system

Abstract

The invention provides a data processing method and device for synchronous interpolation of upper and lower special-shaped planes generated by an all-digital linear cutting numerical control system. The method comprises the following steps: firstly, generating an interpolation angle sequence and a coordinate point set based on a reference surface of a workpiece, and iteratively calculating non-reference surface data by using a parameter equation, so as to construct special-shaped plane interpolation data; then, an interpolation point set of a UV plane is calculated by establishing a taper model and combining a geometric projection algorithm so as to ensure that an interpolation track can be accurately matched with a space contour of a workpiece. And finally, realizing a coordinate data set of an XY plane by adopting mechanical transmission and a coordinate increment algorithm, constructing a five-dimensional interpolation array, processing by adopting an off-line calculation and synchronous interpolation method, simultaneously performing speed regulation based on a subdivision mode, taking out a group of data from a processing buffer area in each period, calculating an interpolation amount and sending the interpolation amount to a driver, and completing the processing of the XY plane. And a numerical control system can execute a four-axis linkage interpolation instruction to complete efficient machining of complex special shapes.

Description

Technical Field

[0001] The present invention relates to the technical field of interpolation methods for numerical control systems, and particularly to a data processing method and device for generating synchronous interpolation of upper and lower shaped planes in a full digital wire cutting numerical control system. Background Art

[0002] In the field of numerical control machining, achieving high-precision machining of upper and lower shaped parts has always been a technical challenge faced by the manufacturing industry. Especially in industries such as aerospace, mold manufacturing, and precision machining, traditional two-dimensional interpolation methods are difficult to meet the machining requirements of complex shaped parts. With the wide application of wire cutting machines in industries such as mold machining, the demand for cutting large taper and upper and lower shaped parts is increasing. However, achieving high-precision machining of upper and lower shaped parts remains one of the core problems in wire cutting technology. Especially in terms of control algorithms, how to ensure machining accuracy and stability has always been the focus of research. In the traditional wire cutting method for machining upper and lower shaped parts, the pulsed motor is controlled by pulse signals. However, due to the electromagnetic interference of the high-frequency power supply, additional shielding measures are often required. In addition, the stepper motor uses open-loop control and lacks a real-time feedback mechanism, unable to automatically compensate for position errors, which affects machining accuracy. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a data processing method and device for generating synchronous interpolation of upper and lower shaped planes in a full digital wire cutting numerical control system, which effectively avoids the reduction in accuracy caused by interference or loss of pulse signals.

[0004] To achieve the above purpose, the present invention adopts the following technical solutions: A data processing method for generating synchronous interpolation of upper and lower shaped planes in a full digital wire cutting numerical control system, specifically including the following steps:

[0005] Step S1: Select a reference plane and initialize interpolation conditions to generate a first data matrix containing an angle sequence and a coordinate point set;

[0006] Step S2: Process the non-reference plane data based on the angle parameters of the first matrix to generate a second data matrix for mapping the angles and coordinates of the shaped plane;

[0007] Step S3: Establish a taper model and calculate the interpolation point set in the UV plane to generate a third data matrix containing dynamic taper parameters;

[0008] Step S4: Scale and map the third matrix to the XY plane according to the mechanical transmission ratio and compensate the coordinates to generate a fourth data matrix;

[0009] Step S5: Integrate the angles, XY plane compensated coordinates, and UV plane taper coordinates to generate a composite interpolation instruction set executable by the numerical control system;

[0010] Step S6: Dynamically adjust the adjustment coefficient according to the real-time change of the discharge state, and index the composite instruction set to optimize the feed rate in the next interpolation cycle, so as to achieve better optimization of the machining effect.

[0011] In a preferred embodiment, an interpolation sequence is generated through offline calculation and packed into a data frame and sent to the driver to ensure precise control and stable operation during the machining process; in Step S1, the upper / lower plane of the workpiece is selected as the reference plane, and the double-plane interpolation conditions are initialized based on the machining parameters. At the same time, the speed adjustment is realized by means of subdivision, and a first data matrix containing the angle sequence of the reference graph and the corresponding coordinate point set is generated through a parametric interpolation algorithm; in Step S2, according to the angle parameter set of the first data matrix, the non-reference plane is iteratively processed by using parametric equations to generate a second data matrix containing the angle-coordinate mapping relationship of the special-shaped plane; in Step S3, a taper model is established based on the workpiece thickness T, the distance H between the upper and lower guide wheels, and the interpolation point set of the UV plane is calculated through a geometric projection algorithm to generate a third data matrix containing dynamic taper parameters; in Step S4, according to the mechanical transmission ratio of the distance H1 between the lower guide wheel and the lower surface of the workpiece to the total height H of the upper and lower guide wheels, the third data matrix is scaled proportionally and mapped to the XY plane through a geometric projection algorithm, and the interpolation point set of the XY plane is compensated by using a coordinate increment algorithm to generate a fourth data matrix of the XY plane containing the mechanical compensation amount; in Step S5, a five-dimensional interpolation array indexed by the polar angle parameter is established, integrating the angle parameter, the compensation coordinates of the XY plane and the taper coordinates of the UV plane to generate a composite interpolation instruction set executable by the numerical control system; in Step S6, the system determines the real-time change of the discharge state according to the current value fed back by the high-frequency power supply during the interpolation process and dynamically adjusts the adjustment coefficient.

[0012] In a preferred embodiment, Step S1 specifically includes:

[0013] Select the upper plane or the lower plane of the workpiece as the parametric reference, input the initial machining speed v, the electrode wire diameter Process parameters, calculate the perimeter C of the plane according to the selected reference plane and plane parameters, and then according to the speed v and interpolation cycle t given by the machining parameters:

[0014]

[0015] In the formula:

[0016] Step is the total number of steps for the plane interpolation;

[0017] The dynamic speed adjustment during the machining process is realized by a flexible speed regulation method based on the subdivision interpolation sequence: Let the original total number of steps be Step, and by introducing a subdivision coefficient n ∈ N +The total number of steps is extended to S = n × Step to generate an interpolation sequence with n - fold data density. During the interpolation execution phase, the target point coordinates in the interpolation sequence are indexed in real - time by dynamically adjusting the coefficient k ≥ 1. The continuous and smooth adjustment of the speed is achieved by changing the magnification parameter k, and the feed rate of the next interpolation cycle is adjusted while ensuring that the interpolation points are always located on the theoretical machining trajectory.

[0018] In a preferred embodiment, according to the starting point and the ending point in the initial conditions, the initial angle and the termination angle are calculated, and then the included angle β between the initial angle and the termination angle is calculated. At this time, the linear velocity is converted into an angular step Δθ through polar - coordinate discretization processing:

[0019]

[0020] Finally, the polar - angle sequence {θ i} of the reference plane and the corresponding Cartesian - coordinate set {x i , y i} are generated by iterative calculation using parametric equations, and the first data matrix M1 = {θ i , x1 i , y1 i} is constructed. S represents the total number of steps; x1 i , y1 i represent the reference - plane coordinates in the Cartesian coordinate system.

[0021] In a preferred embodiment, step S2 specifically includes:

[0022] Substitute the polar - angle sequence {θ i} in the first data matrix M1 into the parametric equations of the non - reference plane for iterative calculation to generate the polar - angle sequence {θ i} of the non - reference plane and the corresponding Cartesian - coordinate set {x i , y i}, and construct the second data matrix M2 = {θ i , x2 i , y2 i}. x2 i , y2 i represent the non - reference - plane coordinates in the Cartesian coordinate system.

[0023] In a preferred embodiment, step S3 specifically includes:

[0024] Assume that the first data matrix M1 is the upper plane of the workpiece and the second data matrix M2 is the lower plane of the workpiece. At the same θ i angle, there is:

[0025]

[0026] In the formula: T represents the interpolation cycle;

[0027] where α is the instantaneous taper angle, and L x , L u respectively represent the lengths of the upper and lower planes corresponding to the current instantaneous taper angle. Through the geometric projection formula:

[0028]

[0029] generate a set of interpolation points on the UV axis {U i , V i}, and form the third data matrix M3 = {θ i , U i , V i}; where U i represents the coordinate point on the U-axis plane, and H represents the total height of the upper and lower guide wheels; U i , V i represent a set of interpolation points on the UV plane coordinates indexed by θ i .

[0030] In a preferred embodiment, step S4 specifically includes:

[0031] Adopt the mechanical transmission compensation coefficient to achieve it by the method of coordinate increment:

[0032] When i = 0,

[0033] X0 = U0 · k

[0034] Y0 = V0 · k

[0035] When i > 0,

[0036] X i = U i · k + (x2 i+1 - x2 i )

[0037] Y i = V i · k + (y2 i+1 - y2 i )

[0038] Generate a set of compensated interpolation coordinates on the XY plane {X i , Y i}, and construct the fourth data matrix M4 = {θ i , X i , Y i}, and x2 i+1 represents the coordinate point of the (i + 1)-th index, which is the next index of the i-th index on the X-axis in the second data matrix generated in step S2.

[0039] In a preferred embodiment, step S5 specifically includes:

[0040] Establish a five-dimensional interpolation array indexed by the polar angle parameter, integrate the angle parameter, the XY plane compensation coordinates and the UV plane taper coordinates, and generate a composite interpolation instruction set executable by the numerical control system; the specific data structure of the five-dimensional interpolation array is as follows:

[0041] {θ i , X i , Y i , U i , V i} i = 1, 2, 3, …, n

[0042] Among them, with θ i as the parameter index, the last two-dimensional parameters control the servo motion of the XY axes, and the last two-dimensional parameters synchronously drive the UV axis taper device to form a four-axis linkage spatial interpolation trajectory.

[0043] In a preferred embodiment, step S6 specifically includes:

[0044] The correspondence between the discharge state and the current:

[0045] Short-circuit state: The current increases significantly, indicating that the electrode wire is in too tight contact with the workpiece. At this time, the feed speed needs to be reduced to avoid short circuit;

[0046] No-load state: The current is close to zero, indicating that the inter-electrode gap is too large. The feed speed needs to be increased to reduce the gap;

[0047] Normal discharge: The current is stable within the target range. At this time, the feed speed matches the material erosion rate, and the machining is the most stable;

[0048] During the machining process, the system determines the real-time change of the discharge state according to the actually measured current in real time, and optimizes the feed amount of the next interpolation cycle by indexing the composite interpolation instruction set by adjusting the adjustment coefficient, so as to keep the current within the optimal range, thereby optimizing the machining effect;

[0049] During the wire electrical discharge machining process, the positive pole of the pulse power supply is connected to the workpiece, and the negative pole of the pulse power supply is connected to the electrode wire; a high-frequency pulse power supply is applied between the workpiece and the electrode wire. The wire spool stores the electrode wire and realizes the circular motion of the electrode wire by means of high-speed pulling. At the same time, an insulating cutting fluid is sprayed in the two moving directions of the electrode wire. When the electrode wire approaches the workpiece and the distance is small enough, the cutting fluid is ionized and broken down, generating high temperature to melt or vaporize the metal, which is discharged from the working surface with the working fluid to form a cut. The waste chips are removed through the flushing system; under the continuous action of the pulse power supply, the shape of the required part is completed; the cutting path in the XY plane is controlled by controlling the translational motion of the worktable;

[0050] In the UV plane, by adjusting the taper of the electrode wire, the cutting angle of the electrode wire on the workpiece can be changed. By adjusting the angle of the upper guide wheel, the contact angle between the electrode wire and the workpiece surface can be changed, thereby controlling the cutting taper.

[0051] The present invention also provides a data processing device for generating synchronous interpolation of upper and lower non-uniform planes in a full-digital wire cutting numerical control system, which runs the data processing method for generating synchronous interpolation of upper and lower non-uniform planes in a full-digital wire cutting numerical control system.

[0052] Compared with the prior art, the present invention has the following beneficial effects: The present invention uses a full-closed-loop bus-type servo motor for processing. Through direct transmission of data frames, it has high control accuracy and strong anti-interference ability, effectively avoiding the reduction in accuracy caused by interference or loss of pulse signals. However, to achieve high-precision upper and lower non-uniform processing, it is still necessary to reconstruct the four-axis linkage interpolation algorithm to ensure synchronous interpolation of the upper and lower planes during the processing. The system generates an interpolation point set through offline calculation and drives the motor in a synchronous interpolation manner to achieve precise processing. At the same time, to ensure the stability of the processing process and cutting accuracy, the system dynamically adjusts the feed speed according to the current value feedback by the high-frequency power supply discharge, and adjusts the cutting speed according to the real-time change of the discharge state, which can effectively optimize the processing effect and ensure the quality of the workpiece surface and processing accuracy. Therefore, researching an efficient and accurate synchronous interpolation algorithm for upper and lower non-uniform planes based on a full-digital wire cutting numerical control system is of great significance for improving processing quality and optimizing the performance of the numerical control system. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] FIG. Figure 1 is the mechanical working principle diagram of the present invention;

[0054] FIG. Figure 2 is the flow schematic diagram of the method of the present invention;

[0055] FIG. Figure 3 is the taper calculation schematic diagram of the method of the present invention;

[0056] FIG. Figure 4 is the taper adjustment schematic diagram of the method of the present invention

[0057] In the figure: 1 - wire spool; 2 - electrode wire; 3 - wire guide wheel; 4 - upper wire guide wheel; 5 - upper guide nozzle; 6 - workpiece; 7 - workbench; 8 - cutting fluid; 9 - lower guide nozzle; 10 - lower wire guide wheel; 11 - conductive block; 12 - high-frequency pulse power supply. DETAILED DESCRIPTION OF THE INVENTION

[0058] The present invention will be further described below in conjunction with the drawings and embodiments.

[0059] It should be noted that the following detailed description is illustrative and aims to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present application belongs.

[0060] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application; as used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should also be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0061] A data processing method for generating synchronous interpolation of upper and lower shaped planes in a fully digital wire cutting numerical control system, referring to Figures 1-4 , specifically includes the following steps:

[0062] Step S1: Select a reference plane and initialize the interpolation conditions to generate a first data matrix including an angle sequence and a coordinate point set.

[0063] Step S2: Based on the angle parameters of the first matrix, process the non-reference plane data to generate a second data matrix for mapping the shaped plane angle-coordinates.

[0064] Step S3: Establish a taper model and calculate the interpolation point set in the UV plane to generate a third data matrix including dynamic taper parameters.

[0065] Step S4: Scale and map the third matrix to the XY plane according to the mechanical transmission ratio and compensate the coordinates to generate a fourth data matrix.

[0066] Step S5: Integrate the angle, XY plane compensated coordinates, and UV plane taper coordinates to generate a composite interpolation instruction set executable by the numerical control system.

[0067] Step S6: Dynamically adjust the adjustment coefficient according to the real-time change of the discharge state and index the composite instruction set to optimize the feed rate in the next interpolation cycle and achieve better optimization of the machining effect.

[0068] Generate an interpolation sequence through offline calculation, and package it into a data frame and send it to the driver to ensure precise control and stable operation during the machining process. In step S1, select the upper / lower plane of the workpiece 6 as the reference plane, initialize the double-plane interpolation conditions based on the machining parameters, and at the same time adopt a subdivision method to achieve speed adjustment. Generate the first data matrix containing the angle sequence of the reference graph and the corresponding coordinate point set through a parametric interpolation algorithm; in step S2, according to the angle parameter set of the first data matrix, use a parametric equation to iteratively process the data of the non-reference plane, and generate the second data matrix containing the angle-coordinate mapping relationship of the special-shaped plane; in step S3, establish a taper model based on the thickness T of the workpiece 6, the distance H between the upper guide wheel 4 and the lower guide wheel 10, calculate the interpolation point set of the UV plane through a geometric projection algorithm, and generate the third data matrix containing dynamic taper parameters; in step S4, according to the mechanical transmission ratio of the distance H1 between the lower guide wheel 10 and the lower surface of the workpiece 6 to the total height H of the upper guide wheel 4 and the lower guide wheel 10, use a geometric projection algorithm to perform an equi-ratio scaling mapping of the third data matrix to the XY plane, and use a coordinate increment algorithm to compensate the interpolation point set of the XY plane, and generate the fourth data matrix of the XY plane containing the mechanical compensation amount; in step S5, establish a five-dimensional interpolation array indexed by the polar angle parameter, integrate the angle parameter, the compensation coordinates of the XY plane, and the taper coordinates of the UV plane, and generate a composite interpolation instruction set executable by the numerical control system. In step S6, the system determines the real-time change of the discharge state according to the current value fed back by the high-frequency power supply during the interpolation process, dynamically adjusts the adjustment coefficient, and adjusts the feed rate of the next interpolation cycle with the index array to optimize the machining effect.

[0069] Step S1 specifically includes:

[0070] Select the upper plane or the lower plane of the workpiece 6 as the parametric reference, input the initial machining speed v, the diameter of the electrode wire 2 and other process parameters. According to the selected reference plane and plane parameters, the perimeter C (unit: mm) of this plane can be calculated. Then, based on the speed v (unit: mm / s) and interpolation cycle t (unit: ms) given by the machining parameters:

[0071]

[0072] In the formula:

[0073] Step is the total number of interpolation steps for this plane.

[0074] To achieve dynamic speed adjustment during the machining process, this study proposes a flexible speed regulation method based on a subdivided interpolation sequence: Let the original total number of steps be Step, and by introducing a subdivision coefficient n ∈ N +Expand the total number of steps to S = n × Step to generate an interpolation sequence with n - fold data density. During the interpolation execution phase, dynamically adjust the coefficient k ≥ 1 to index the target point coordinates in the interpolation sequence in real - time, and achieve continuous and smooth speed adjustment by changing the magnification parameter k, adjust the feed rate of the next interpolation cycle, while ensuring that the interpolation points are always located on the theoretical machining trajectory.

[0075] According to the starting point and the ending point in the initial conditions, the initial angle and the ending angle can be calculated, and then the included angle β between the initial angle and the ending angle can be calculated. At this time, through polar - coordinate discretization processing, the linear velocity is converted into an angular step Δθ:

[0076]

[0077] Finally, use the parametric equation to iteratively calculate to generate the polar - angle sequence {θ i} and the corresponding Cartesian - coordinate set {x i , y i}, and construct the first data matrix M1 = {θ i , x1 i , y1 i};

[0078] Step S2 specifically includes:

[0079] Substitute the polar - angle sequence {θ i} in the first data matrix M1 into the parametric equation of the non - reference plane to iteratively calculate to generate the polar - angle sequence {θ i} and the corresponding Cartesian - coordinate set {x i , y i}, and construct the second data matrix M2 = {θ i , x2 i , y2 i};

[0080] Step S3 specifically includes:

[0081] Assume that the first data matrix M1 is the upper plane of workpiece 6 and the second data matrix M2 is the lower plane of workpiece 6. At the same θ i angle, there is:

[0082]

[0083] In the formula:

[0084] where α is the instantaneous taper angle, L x , L u respectively represent the lengths of the upper and lower planes corresponding to the current instantaneous taper angle. Through the geometric projection formula:

[0085]

[0086] Generate a set of UV-axis interpolation points {U i , V i}, and form the third data matrix M3 = {θ i , U i , V i}.

[0087] Step S4 specifically includes:

[0088] Step S4 uses the mechanical transmission compensation coefficient to be achieved by the method of coordinate increment:

[0089] When i = 0,

[0090] X0 = U0·k

[0091] Y0 = V0·k

[0092] When i > 0,

[0093] X i = U i ·k+(x2 i+1 - x2 i )

[0094] Y i = V i ·k+(y2 i+1 - y2 i )

[0095] Generate a set of XY-plane compensation interpolation coordinates {X i , Y i}, and construct the fourth data matrix M4 = {θ i , X i , Y i}.

[0096] Step S5 specifically includes:

[0097] Establish a five-dimensional interpolation array indexed by the polar angle parameter, integrate the angle parameter, XY-plane compensation coordinates, and UV-plane taper coordinates, and generate a composite interpolation instruction set executable by the numerical control system. The specific data structure of the five-dimensional interpolation array is as follows:

[0098] {θ i , X i , Y i , U i , V i} i = 1, 2, 3,..., n

[0099] Among them, with θ i as the parameter index, the last two-dimensional parameters control the XY-axis servo motion, and the last two-dimensional parameters synchronously drive the UV-axis taper device to form a four-axis linkage spatial interpolation trajectory.

[0100] Step S6 specifically includes:

[0101] The correspondence between the discharge state and the current:

[0102] Short - circuit state: The current increases significantly, indicating that the electrode wire 2 is in too tight contact with the workpiece 6. At this time, the feed speed needs to be reduced to avoid short - circuit;

[0103] No - load state: The current is close to zero, indicating that the inter - electrode gap is too large. The feed speed needs to be increased to reduce the gap.

[0104] Normal discharge: The current is stable within the target range. At this time, the feed speed matches the material erosion rate, and the machining is the most stable.

[0105] During the machining process, the system determines the real - time change of the discharge state according to the actually feedback current in real - time. By adjusting the adjustment coefficient, the feed amount of the next interpolation cycle is optimized with reference to the composite interpolation instruction set, so that the current is maintained within the optimal range, thereby optimizing the machining effect.

[0106] During the wire - cut electrical discharge machining process, the positive pole of the pulse power supply is connected to the workpiece 6, and the negative pole of the pulse power supply is connected to the electrode wire 2. A high - frequency pulse power supply 12 is applied between the workpiece 6 and the electrode wire 2. The spool 1 stores the electrode wire 2 and realizes the cyclic movement of the electrode wire 2 by means of high - speed pulling. At the same time, an insulating cutting fluid 8 is sprayed in two moving directions of the electrode wire 2. When the electrode wire 2 approaches the workpiece 6 and the distance is small enough, the cutting fluid 8 is ionized and broken down, generating high temperature to melt or vaporize the metal, which is discharged from the working surface with the working fluid to form a cut. The waste chips are removed through the flushing system. Under the continuous action of the pulse power supply, the required shape of the part to be cut is completed. The XY plane mainly realizes the precise control of the cutting path by controlling the translational movement of the workbench 7. The UV plane involves the adjustment of the conductive electrode wire 2, especially the role of the upper guide wheel. In the UV plane, the taper adjustment of the electrode wire 2 is to change the cutting angle of the electrode wire 2 on the workpiece 6, and the angle adjustment of the upper guide wheel can change the contact angle between the electrode wire 2 and the surface of the workpiece 6, thereby controlling the cutting taper.

[0107] This method first generates an interpolation angle sequence and a set of coordinate points based on the reference plane of the workpiece 6, and uses parametric equations to iteratively calculate the non-reference plane data, thereby constructing interpolation data for the special-shaped plane. Subsequently, a taper model is established, and combined with the geometric projection algorithm to calculate the interpolation point set in the UV plane to ensure that the interpolation trajectory can accurately match the spatial contour of the workpiece 6. Finally, mechanical transmission and coordinate increment algorithms are used to implement the coordinate data set in the XY plane, and a five-dimensional interpolation array is constructed. The offline calculation and synchronous interpolation methods are used for processing, and the speed is adjusted based on the subdivision method. A set of data is taken from the processing buffer every cycle, the interpolation amount is calculated and sent to the driver, so that the numerical control system can execute the four-axis linkage interpolation instruction to complete the efficient processing of complex special shapes.

Claims

1. A data processing method for generating synchronous interpolation of upper and lower special-shaped planes in a fully digital wire cutting numerical control system, characterized in that: The specific steps include: Step S1: Select a reference plane and initialize interpolation conditions to generate a first data matrix including an angle sequence and a coordinate point set; Step S2: Based on the angle parameters of the first matrix, the non-reference surface data is processed to generate a second data matrix of the special-shaped plane angle-coordinate mapping; Step S3: establishing a taper model and calculating a UV plane interpolation point set to generate a third data matrix containing dynamic taper parameters; Step S4: scaling and mapping the third matrix to the XY plane according to the mechanical transmission ratio, and compensating the coordinates to generate a fourth data matrix; Step S5: integrating the angle, the XY plane compensation coordinates and the UV plane taper coordinates to generate a composite interpolation instruction set executable by the numerical control system; Step S6: According to the real-time change of the discharge state, the adjustment coefficient is dynamically adjusted, and the composite instruction set is indexed to optimize the feed amount of the next stage interpolation cycle to achieve better optimization of the processing effect.

2. According to claim 1, a data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system, characterized in that: An interpolation sequence is generated through offline calculation, and it is packaged into a data frame and sent to the driver to ensure precise control and stable operation during the processing; in step S1, the upper / lower plane of the workpiece is selected as the reference plane, and the dual-plane interpolation conditions are initialized based on the processing parameters. At the same time, a subdivision method is used to achieve speed regulation, and a first data matrix containing a reference graphic angle sequence and a corresponding coordinate point set is generated through a parameterized interpolation algorithm; in step S2, according to the angle parameter set of the first data matrix, a parametric equation is used to iteratively process the non-reference surface data to generate a second data matrix containing a special-shaped plane angle-coordinate mapping relationship; in step S3, a taper model is established based on the workpiece thickness T and the upper guide wheel and lower guide wheel spacing H, and the UV plane interpolation point set is calculated through a geometric projection algorithm to generate a third data matrix containing dynamic taper parameters; In step S4, according to the mechanical transmission ratio of the lower guide wheel-the lower surface distance H1 of the workpiece and the total height H of the upper guide wheel and the lower guide wheel, a geometric projection algorithm is used to perform geometric scaling and mapping of the third data matrix to the XY plane, and a coordinate increment algorithm is used to compensate the XY plane interpolation point set to generate an XY plane fourth data matrix containing the mechanical compensation amount; in step S5, a five-dimensional interpolation array indexed by the polar angle parameter is established, and the angle parameters, XY plane compensation coordinates and UV plane taper coordinates are integrated to generate a composite interpolation instruction set executable by the CNC system; in step S6, the system determines the real-time change of the discharge state according to the current value of the high-frequency power supply discharge feedback during the interpolation process, and dynamically adjusts the adjustment coefficient.

3. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 2 is characterized in that: Step S1 specifically includes: Select the upper or lower plane of the workpiece as the parametric reference, input the initial processing speed v, electrode wire diameter Process parameters, calculate the perimeter C of the plane based on the selected reference plane and plane parameters, and then calculate the speed v and interpolation cycle t based on the given processing parameters: Where: Step is the total number of steps for the plane interpolation; The dynamic speed regulation in the machining process is realized by a flexible speed regulation method based on subdivision interpolation sequence: Let the original total number of steps be Step, and by introducing the subdivision coefficient n∈N + The total number of steps is expanded to S = n × Step to generate an interpolation sequence with n times the data density. In the interpolation execution stage, the target point coordinates in the interpolation sequence are indexed in real time through the dynamic adjustment coefficient k ≥ 1, and the speed is continuously and smoothly adjusted by changing the magnification parameter k to adjust the feed amount of the next interpolation cycle, while ensuring that the interpolation point is always on the theoretical machining trajectory.

4. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 3 is characterized in that: According to the starting point and end point in the initial conditions, the initial angle and the end angle are calculated, and then the angle β between the initial angle and the end angle is calculated. At this time, the linear velocity is converted into an angle step Δθ through polar coordinate discretization: Finally, the parametric equation is used to iteratively calculate the polar angle sequence {θ i } and the corresponding Cartesian coordinate set {x i ,y i }, construct the first data matrix M1 = {θ i ,x1 i ,y1 i }, S represents the total number of steps; x1 i ,y1 i Represents the coordinates of the reference plane in the Cartesian coordinate system.

5. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 2 is characterized in that: Step S2 specifically includes: According to the polar angle sequence {θ i }Substitute the parametric equation of the non-reference surface into the iterative calculation to generate the polar angle sequence of the non-reference surface {θ i } and the corresponding Cartesian coordinate set {x i ,y i }, construct the second data matrix M2 = {θ i ,x2 i ,y2 i }, x2 i ,y2 i Represents non-reference plane coordinates in the Cartesian coordinate system.

6. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 2 is characterized in that: Step S3 specifically includes: Assume that the first data matrix M1 is the upper plane of the workpiece, and the second data matrix M2 is the lower plane of the workpiece. i At this angle, we have: Where: T represents the interpolation period; Where α is the instantaneous taper angle, L x , L u Respectively represent the length of the upper and lower planes corresponding to the current instantaneous taper angle, through the geometric projection formula: Generate UV axis interpolation point set {U i ,V i }, forming the third data matrix M3 = {θ i ,U i ,V i }; Among them, U i Indicates the coordinate point of the U-axis plane, H indicates the total height of the upper guide wheel and the lower guide wheel; U i ,V i Indicated by θ i A set of interpolated points in the UV plane indexed by the coordinates.

7. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 2 is characterized in that: Step S4 specifically includes: Adopt mechanical transmission compensation coefficient This is achieved by using the coordinate increment method: When i=0, X0=U0·k Y0=V0·k When i>0, X i =U i ·k+(x2 i+1 -x2 i ) Y i =V i ·k+(y2 i+1 -y2 i ) Generate XY plane compensation interpolation coordinate set {X i ,Y i }, construct the fourth data matrix M4 = {θ i ,X i ,Y i }, x2 i+1 It represents the coordinate point of the i+1th index following the i-th index on the X-axis in the second data matrix generated in step S2.

8. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 2 is characterized in that: Step S5 specifically includes: A five-dimensional interpolation array with polar angle parameters as index is established, which integrates angle parameters, XY plane compensation coordinates and UV plane taper coordinates to generate a composite interpolation instruction set executable by the CNC system; the specific five-dimensional interpolation array data structure is as follows: {θ i ,X i ,Y i ,U i ,V i }i=1,2,3,…,n Among them, θ i It is the parameter index, the next two dimensional parameters control the XY axis servo motion, and the last two dimensional parameters synchronously drive the UV axis taper device to form a four-axis linkage spatial interpolation trajectory.

9. The data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system according to claim 2 is characterized in that: Step S6 specifically includes: The corresponding relationship between discharge state and current: Short circuit state: The current increases significantly, indicating that the electrode wire is in too tight contact with the workpiece. At this time, the feed speed needs to be reduced to avoid short circuit; No-load state: The current is close to zero, indicating that the gap between the electrodes is too large and the feed speed needs to be increased to reduce the gap; Normal discharge: The current is stable within the target range. At this time, the feed speed matches the material removal rate and the processing is most stable. During the machining process, the system determines the real-time change of the discharge state based on the actual current feedback, and optimizes the feed rate of the next interpolation cycle by adjusting the adjustment coefficient and indexing the composite interpolation instruction set to keep the current in the optimal range, thereby optimizing the machining effect. During the EDM wire cutting process, the positive pole of the pulse power supply is connected to the workpiece, and the negative pole of the pulse power supply is connected to the electrode wire; a high-frequency pulse power supply is added between the workpiece and the electrode wire, and the wire drum stores the electrode wire and realizes the circulation movement of the electrode wire by high-speed pulling. At the same time, insulating cutting fluid is sprayed in the two movement directions of the electrode wire. When the electrode wire approaches the workpiece and the distance is small to a certain extent, the cutting fluid is ionized and broken down, generating high temperature to melt or gasify the metal, and the working fluid is discharged from the working surface to form a cut, and the waste chips are removed through the flushing system; under the continuous action of the pulse power supply, the shape of the part to be cut is completed; the XY plane controls the translation movement of the worktable to realize the control of the cutting path; In the UV plane, the cutting angle of the electrode wire on the workpiece is changed by adjusting the taper of the electrode wire, and the contact angle between the electrode wire and the workpiece surface is changed by adjusting the angle of the upper guide wheel, thereby controlling the cutting taper.

10. A data processing device for generating synchronous interpolation of upper and lower special-shaped planes in a fully digital wire cutting numerical control system, characterized in that: A data processing method for generating synchronous interpolation of upper and lower special-shaped planes by a fully digital wire cutting numerical control system as described in any one of claims 1 to 9 is run.

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