An embedded numerical control electro-machining system

Abstract

The application discloses an embedded numerical control electro-processing system and relates to the technical field of numerical control electro-processing.The application comprises a processing unit, a power management unit, a console, a planning module and a coordination module, wherein the processing unit comprises an ARM unit, a DSP unit, a five-axis motor control module, an HDMI module, an RJ45-HUB, a USB-HUB, an FPGA unit, a hand wheel serial port, an RS485 serial port and an IO signal processing module; the power management unit comprises a protection module and a filtering module; the port of the console is in communication with the port of the planning module; the output end of the planning module is connected with the input end of the coordination module; the output end of the ARM unit is connected with the input end of the planning module; and the port of the coordination module is in communication with the port of the ARM unit.The planning module of the application can automatically generate a production plan and automatically update and optimize the production plan according to the establishment of a general production model, so that the production plan is more reasonable, and the coordination module can intelligently schedule the processing tasks and graphic calculation.

Description

Technical Field

[0001] This invention relates to the field of CNC electrical discharge machining technology, specifically to an embedded CNC electrical discharge machining system. Background Technology

[0002] Electrical discharge machining (EDM) uses the energy of pulsed discharge to remove material, so it is not limited by the hardness of the material and can process any conductive material, including difficult-to-machine materials with high hardness, high strength, and high toughness. By controlling the shape and movement trajectory of the electrodes, various complex-shaped parts can be precisely machined without the need for complex tooling and multiple processes. Since the energy of the pulsed discharge is concentrated in a very small area, the thermal impact on the surface of the part is small, thus achieving better surface quality and reducing subsequent processing steps.

[0003] Current electrical discharge machining (EDM) equipment is not highly automated and requires manual operation and monitoring, making it difficult to improve enterprise production efficiency. While integrating design and manufacturing can simplify the parts processing steps, this approach can only improve the production efficiency of a single machine or a machine of the same model. It cannot achieve collaborative processing of multiple or different models of EDM equipment, nor can it achieve automatic production planning and intelligent scheduling based on graphic calculations. Therefore, it is not suitable for large-scale EDM applications. Designing a CNC EDM system that automatically arranges production plans and enables multi-machine collaborative operation is a technical problem that needs to be solved by those skilled in the art. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an embedded CNC electrical discharge machining system, which solves the problems mentioned in the background section.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an embedded CNC electrical discharge machining system, comprising a machining unit, a power management unit, a control console, a planning module, and a coordination module. The machining unit includes an ARM unit, a DSP unit, a five-axis motor control module, an HDMI module, an RJ45-HUB, a USB-HUB, an FPGA unit, a handwheel serial port, an RS485 serial port, and an IO signal processing module. The power management unit includes a protection module and a filtering module. The port of the control console communicates with the port of the planning module. The output of the planning module is connected to the input of the coordination module. The output of the ARM unit is connected to the input of the planning module. The input terminal of the power management unit is connected to the input terminal of the processing unit. The port of the collaborative module establishes communication with the port of the ARM unit. The output terminal of the power management unit is electrically connected to the input terminal of the processing unit. The port of the ARM unit establishes communication with the ports of the DSP unit, the five-axis motor control module, the RJ45-HUB, the USB-HUB, the FPGA unit, and the RS485 serial port. The port of the DSP unit establishes communication with the port of the five-axis motor control module. The output terminal of the ARM unit is connected to the input terminal of the HDMI module. The output terminal of the handwheel serial port is connected to the input terminal of the FPGA unit. The port of the IO signal processing module establishes communication with the port of the FPGA unit.

[0006] The ARM unit is a TIAM572x chip with a Cortex-A15 core architecture, providing powerful computing capabilities suitable for handling high-level control logic, graphical interfaces, and task scheduling functions. The ARM core supports the operation of drawing and machining software, providing users with real-time monitoring, interactive operation interfaces, and display and control of machining paths. The AM572x provides a variety of industrial-grade interfaces, such as SPI, I2C, Ethernet, and UART, which can easily connect to external devices and sensors, supporting efficient data transmission and real-time communication. The main operating system is Linux, which provides an open development environment and a rich software ecosystem for upper-level applications, facilitating development and maintenance. Linux's multi-task scheduling function enables the system to handle multiple tasks simultaneously, such as machining control, path planning, and user interface. The stability and openness of the Linux system allow the system to use mature drawing and path planning software tools, such as CAD and CAM software, to achieve more accurate machining paths and graphic drawing. The system supports multiple storage methods and high-speed data exchange, such as eMMC and SD cards, ensuring the speed and reliability of data storage.

[0007] The FPGA unit, consisting of an FPGA chip, is primarily responsible for controlling the peripheral infrastructure of the handwheel serial port and acquiring signals from the limit I / O signal processing module. Its features and advantages are as follows:

[0008] For peripheral device control, the FPGA unit can directly control external devices, such as motor drives, actuators and sensors, through parallel processing, providing hardware-level control. Compared with software control, the FPGA unit can respond to the needs of external devices more efficiently and with lower latency, ensuring the real-time performance and stability of the system.

[0009] Limit signal acquisition: The FPGA is responsible for acquiring data from external limit switches and sensors, and through real-time hardware processing, it ensures the accurate transmission and response of limit signals. This function is crucial for ensuring equipment safety during the processing.

[0010] Customization and high parallelism: The programmability of FPGA units allows for the customization of control logic according to actual needs, supports multi-channel parallel processing, and enables simultaneous control and signal acquisition of multiple devices, thereby improving the real-time processing capability of the system.

[0011] With low latency and high reliability, the FPGA unit provides low-latency hardware response, ensuring that the system can quickly process external signals, especially in the process of limit signal acquisition and equipment control, which greatly reduces the potential risks caused by latency.

[0012] The DSP unit is a digital signal processing unit responsible for motor data processing and signal transmission of the five-axis motor control module. The DSP is specifically designed to process real-time signals for motor control, ensuring precise adjustment and motion control of the motor to meet high-precision machining requirements. The DSP unit can perform complex mathematical calculations in a very short time, ensuring the accuracy and stability of motor control. Since the DSP is a hardware acceleration unit, it can avoid the latency of traditional processors, ensuring low latency and high-efficiency response of the motor control system.

[0013] The TIAM572x chip + FPGA chip hardware architecture fully leverages the respective advantages of the ARM processor, DSP unit, and FPGA chip, providing the wire EDM system with powerful computing capabilities, flexibility, and real-time response. Based on the AM572x ARM core + DSP + FPGA architecture, the new system maximizes the advantages of each hardware module. The ARM core runs the Linux system and is responsible for high-level control, drawing, and machining tasks; the DSP unit focuses on precise motor control; and the FPGA handles peripheral control and limit signal acquisition. Through this efficient collaborative work, the system not only possesses powerful computing and processing capabilities but also ensures precise control and real-time response, meeting the demands of modern wire EDM systems for efficiency, precision, and stability.

[0014] The RS485 serial port and RJ45-HUB are used to communicate with external sensors or devices, the HDMI module is used to output the graphical interface to the monitor for users to view, and the USB-HUB is used to connect input devices such as keyboards and mice.

[0015] The power management unit is used to supply power to the entire processing unit. The filtering module is used to filter the power input to avoid power instability, and the protection module is used for power overload protection to prevent damage to the processing unit.

[0016] The planning module is used to obtain the production plan and break it down into processing tasks, specifically:

[0017] The planning module obtains the equipment model corresponding to the processing unit from each ARM unit. The planning module breaks down the production plan into several processing tasks according to the equipment model and transmits them to the collaboration module. The collaboration module transmits the processing tasks to the corresponding ARM unit. The processing sequence corresponds one-to-one with each processing unit.

[0018] There are two ways to obtain production plans:

[0019] One method involves the user inputting the production plan via a console and transmitting it to the planning module. The other method involves the planning module retrieving production data from the ARM unit of each processing unit and compiling it into a production plan. Specifically:

[0020] During the production data acquisition phase, the user inputs the part drawings to be processed into the ARM unit using an input device plugged into the USB-HUB. When the processing unit processes the part according to the part drawings, the ARM unit records the production data of the part. The production data includes the processing parameters, processing time, and processing path of the part. The ARM unit uses the MD5 checksum algorithm to verify the production data and obtain the corresponding checksum. The checksum is used to verify the integrity of the production data, prevent changes in the production data, and also prevent parts with similar production data from interfering with each other, thus avoiding data deviations from affecting the generation of the production plan. The ARM unit packages the production data and the corresponding checksum and transmits them to the planning module for storage. The production data serves as historical data of the processing of each part, which can effectively quantify the characteristics of the processing of each part, facilitating data analysis and improving the executability of the production plan.

[0021] During the production data collection phase, the planning module performs cross-simulation based on the production data and the corresponding equipment models of the processing units to obtain a compatibility list and a conflict list. The planning module then categorizes the production data and equipment models according to these lists. It counts the frequency of each production data point and each equipment model in the compatibility list (denoted as JR) and the frequency of each production data point and each equipment model in the conflict list (denoted as CT). When the JR of a production data point or equipment model is greater than its own CT, the planning module places it in the first tier; when the JR of a production data point or equipment model is equal to its own CT, it places it in the second tier; when the JR of a production data point or equipment model is equal to its own CT, it places it in the third tier. When the JR of a particular equipment model is less than its own CT, the planning module will list the production data or equipment model as the third tier. When generating a production plan, the planning module will first obtain production data or equipment models from the third tier for matching. After matching, it will then obtain production data or equipment models from the second tier for matching, and finally obtain production data or equipment models from the first tier for matching. After all production data and equipment models are matched, the production plan is obtained. The production data and equipment models in the first tier have strong compatibility and can be arranged for production more flexibly. However, the production data and equipment models in the third tier are not compatible with each other. Therefore, the third tier, which has weaker applicability, will be arranged for production first, while the first tier, which has greater flexibility, will be arranged for production last.

[0022] It should be noted that each time the planning module obtains production data from any processing unit, it performs a checksum comparison. The checksum corresponding to the newly obtained production data is compared with all the checksums stored in the module. If the checksums match, it means that the newly obtained production data is duplicated, and the newly obtained production data is not recorded. Conversely, if the checksums do not match, it means that the newly obtained production data is not duplicated, and the newly obtained production data is saved. Through the above method, the planning module can realize real-time updates of production data during processing, thereby improving the flexibility of production plan optimization.

[0023] The specific steps for cross-simulation are as follows:

[0024] The planning module will count the number of processing unit equipment models. For each equipment model, a simulation environment will be established. The planning module will perform conditional matching on the production data. Specifically, the production data recorded by the processing unit itself will be matched with the processing units of other equipment models except for its own equipment signals. The matching degree between the production data and the equipment model will be calculated based on the processing size, processing time, and processing path. For example, the processing size height requirement of part A is 120mm, while the maximum processing height of the processing unit of equipment model B is 100mm. The planning module will compare each parameter in the production data in turn to determine whether the production data matches the processing unit of the equipment model. If the match is successful, the planning module will mark the production relationship between the successfully matched production data and the corresponding equipment model as processing compatible. Conversely, if the match is unsuccessful, the planning module will mark the production relationship between the unsuccessfully matched production data and the corresponding equipment model as processing conflict. The planning module will establish a compatibility list and a conflict list. Processing compatible production relationships will be saved to the compatibility list, and processing conflicting production relationships will be saved to the conflict list. Each production data and equipment model has multiple production relationships. Therefore, the applicability of the production data and equipment model can be judged by the number of production relationships.

[0025] The specific steps for breaking down a production plan into processing tasks are as follows:

[0026] The planning module establishes a general production model, which is the RT-X general model. This model automatically breaks down the production plan into processing tasks. By continuously modifying the processing plan, the user's modifications can be used to train the general production model, making the breakdown of processing tasks more and more reasonable. The console retrieves the production plan from the planning module, and the user can directly execute or modify the production plan through the console. When executing the production plan, the general production model merges several production data according to the matching relationship in the production plan to obtain processing tasks and transmits the processing tasks to the designated processing units. The processing tasks are arranged in the order of the third echelon, the second echelon, and the first echelon, making the matching of production data with each processing unit more reasonable. It should be noted that multiple processing units can be of the same equipment model. The number of processing units for each equipment model is determined according to the user's actual processing needs. The ARM in the processing unit processes parts according to the processing tasks.

[0027] When modifying the production plan, users can modify the processing tasks of each processing unit through the console, transfer production data, and adjust the processing order of processing units. Specifically, they can transfer production data between processing units of the same equipment model, adjust the processing order of production data within a processing unit, and adjust the time for different processing units to execute processing tasks.

[0028] If a user modifies the production plan through the console, the planning module records the modification steps. Conversely, if a user executes the production plan directly through the console, the planning module does not record the modification steps. Saving the user's modification steps can serve as a training dataset, facilitating subsequent improvement and optimization of the general production model. After the user makes modifications through the console, the planning module updates the production plan in real time and simulates the operation. The simulation is performed by calculating the processing time required for each production data point and performing a rapid simulation in chronological order. If the planning module detects that there are processing units in the production plan that are idle, it marks the cumulative idle time of that processing unit as a processing void and transmits it to the console for the user to view, thus providing timely reminders. If the planning module does not detect any processing units in the production plan that are idle, it does not perform any operations.

[0029] The console is equipped with a display screen and a keyboard and mouse for input. Users can interact with the console using the keyboard, mouse, and display screen to perform operations such as modifying production plans.

[0030] When all processing units execute processing tasks, the collaboration module obtains the running status and computing load of each ARM unit in real time. The computing load is mainly reflected in the real-time rendering of the ARM unit. The collaboration module has a preset trigger threshold of 95% and a preset saturation threshold of 85%. When the computing load of an ARM unit exceeds the trigger threshold, the collaboration module distributes the computing load of the trigger threshold to the ARM units of other processing units of the same equipment model. The collaboration module calculates the average computing load of ARM units of the same equipment model in real time. When the average computing load exceeds the saturation threshold, the collaboration module distributes the computing load of the trigger saturation threshold to the ARM units of processing units of other equipment models.

[0031] When the ARM unit is in an abnormal operating state, the abnormal operating state includes the processing unit unexpectedly stopping the processing task and the component failure. The coordination module will distribute the unfinished processing tasks of the ARM unit in the abnormal operating state to the ARM units of other processing units of the same equipment model to continue to execute the processing tasks. The ARM unit in the abnormal operating state can continue to share the computing load. The ARM unit reports the abnormal operating state to the planning module. The planning module records the abnormal event and marks the event level as general.

[0032] When two or more ARM units of the same equipment model are in an abnormal operating state, the coordination module will distribute the unfinished processing tasks of the abnormal ARM units to ARM units of other equipment models to continue the processing tasks. The ARM units will report the abnormal operating state to the planning module, and the planning module will record the abnormal event and mark the event level as severe.

[0033] The planning module will then adjust the production plan according to the event level of the abnormal event. Specifically, production data and equipment models with a general event level will be downgraded from the first tier to the second tier or from the second tier to the third tier. No action will be taken if they were originally in the third tier. All production data and equipment models with a severe event level will be included in the third tier. If they were originally in the third tier, the corresponding abnormal event will be output to the console for users to view.

[0034] Furthermore, this system is an integrated design and manufacturing system, realizing the integration of design and manufacturing, abandoning the traditional fragmented multi-system model. Users can directly complete graphic design, path planning, and parameter settings within the system without relying on third-party software. Specifically:

[0035] OpenGL accelerates graphics rendering and real-time rendering. X8 and AutoCAD rely on traditional CPU rendering to handle complex graphics and a large number of primitives. As the complexity of graphics increases, the rendering speed may decrease significantly, especially during the visualization of complex designs or large-scale workpieces, resulting in interface lag and operation delays. Although AutoCAD provides graphics rendering acceleration options, it still cannot achieve the performance of efficiently handling complex models and large graphics. Especially when the number of graphics increases sharply, rendering and interface responsiveness will be affected. The new system introduces OpenGL to accelerate graphics rendering, using the hardware acceleration capabilities of the GPU to render graphics in real time, solving the performance bottleneck in the traditional CPU rendering solution. When processing complex or large numbers of graphics, the system can maintain a rendering speed of more than 30 FPS. Even when processing complex 3D workpieces, it can still maintain a smooth operating interface. OpenGL technology, through hardware acceleration rendering, not only reduces the CPU's computational burden, but also optimizes the rendering process of frustum culling, rasterization, and texture mapping, so that even when there are many graphics, it can still maintain a high frame rate and high response speed, greatly improving the user's interactive experience.

[0036] The RTree primitive lookup algorithm and optimized object snapping: While AutoCAD and X8 offer basic object snapping functionality, they still suffer from performance bottlenecks when searching for a large number of graphics in complex scenes. When the number of graphics is excessive, the response speed of the snapping operation often decreases, resulting in a poor user experience, especially during intensive primitive searches where delays may occur. The new system introduces the RTree primitive lookup algorithm, which optimizes the efficiency of graphic search by spatial indexing and partitioning primitives. Particularly in complex workpiece design, it enables fast and accurate object snapping. This algorithm utilizes an R-tree data structure for spatial indexing of primitives, reducing unnecessary search calculations and accurately locating target objects, significantly improving the speed and accuracy of object snapping. RTree reduces the complexity of query operations by dynamically balancing the tree structure, enabling rapid response when processing a large number of graphics without interface lag or operational delays. This greatly improves work efficiency for users who need to efficiently snap and manipulate large numbers of graphics.

[0037] While AutoCAD and X8 support basic path planning, they are mostly used for 2D or simple 3D path design. For scenarios requiring multi-tool cutting or complex machining, traditional software usually requires users to manually divide the path or cannot automatically generate multi-tool cutting paths. The new system, through its path generation and multi-tool trajectory optimization function, can automatically decompose the machining path into trajectories suitable for multi-tool cutting and export standard G / 3B code. Through intelligent path decomposition, the system can automatically determine which paths are suitable for multi-tool cutting and generate corresponding cutting trajectories according to specific requirements. This greatly improves the efficiency and accuracy of CNC machining, especially for workpieces that require staged or complex path cutting. Compared with the manual path design of traditional software, the system can automatically optimize the cutting path, reduce manual intervention, improve machining accuracy, and shorten machining time. The multi-tool trajectory generation and code output functions seamlessly connect with the machining process of CNC machine tools, reducing the production cycle of workpieces and errors in manual operation.

[0038] For drawing and generating unconventional quadratic curves, AutoCAD and X8 support drawing some basic standard curves, such as circles or straight lines. However, for complex quadratic curves such as ellipses, gears, and spline curves, manual drawing or plugins are usually required. Moreover, these software programs do not directly support generating corresponding machining codes and usually require other external tools. The new system supports drawing and generating unconventional quadratic curves such as ellipses, gears, and spline curves. The system has a built-in high-precision curve drawing algorithm that can automatically generate corresponding G / 3B codes to meet high-precision machining requirements. For drawing and generating codes for complex shapes, the system adopts mathematical modeling and precise calculation methods, avoiding the tediousness of traditional manual drawing or external plugins. The system processes these curves automatically, thereby significantly improving design efficiency and machining accuracy.

[0039] The new system features intelligent parsing and syntax checking of G / 3B code. While AutoCAD and X8 typically provide basic code generation for G-code output, they lack built-in intelligent parsing or syntax checking capabilities. Users may need to rely on external tools or manually verify the code's correctness, which can easily lead to errors, especially in the machining of complex workpieces. Incorrect code can cause machining failures or material waste. The new system features intelligent parsing, editing, and syntax checking of G / 3B code. The system can automatically analyze the generated code, detect potential syntax and path errors, and provide correction suggestions. This effectively avoids machining problems caused by non-standard code, improving system stability and reliability. The intelligent parsing function can automatically identify and repair erroneous code in real time, reducing the time spent on manual inspection and correction, greatly improving work efficiency, and reducing the risk of machining failures, ensuring safety and accuracy during the machining process.

[0040] The XYUV 4-axis linkage algorithm and multi-dimensional path control: AutoCAD and X8 path planning are usually based on two-dimensional or simple three-dimensional paths, which are difficult to directly support complex multi-axis linkage. For complex paths such as vertical, tapered, and irregularly shaped paths, special post-processing tools or plugins are usually required to optimize and adjust the path. The new system introduces the XYUV 4-axis linkage algorithm, which supports multi-dimensional path control for complex paths, such as vertical, tapered, and irregularly shaped paths. Through precise multi-axis linkage, the system can control multiple motor axes simultaneously during the machining process, making the path more flexible and accurate. It is particularly suitable for high-precision machining. The algorithm can control the movement of multiple axes at the same time, ensuring the accuracy and stability of the machining path. Especially when dealing with complex geometry, the system can adaptively adjust the path, optimize the machining route, and reduce errors and machining time.

[0041] The new system utilizes OpenGL technology to achieve 3D workpiece trajectory visualization and real-time machining status display. AutoCAD and X8's graphical visualization is typically limited to static displays and does not support real-time tracking of dynamic changes in the workpiece during machining. Users cannot directly see the real-time status of the machining process on the software interface and usually rely on external display devices to obtain real-time data. Users can see the entire machining process through a 3D display, including real-time motor positions and machining paths. This real-time dynamic feedback allows users to adjust or correct the path at any time during machining, improving operational flexibility and accuracy. This function enhances the transparency and control of the production process, enabling users to intuitively understand the machining status and make timely adjustments to ensure coordination between machining accuracy and progress.

[0042] Furthermore, regarding manual path optimization and parameter recommendation, based on its built-in rule base and processing experience, this system provides path optimization suggestions and parameter recommendations. By analyzing the workpiece graphics drawn by the user and combining historical data, the system provides intelligent cutting path planning and processing parameter recommendations. Especially when dealing with different materials, thicknesses, and shapes, the system can automatically recommend the most suitable cutting path and processing settings, greatly improving processing efficiency and material utilization. It also simplifies the user's operation process, reducing tedious work. The system automatically recommends cutting paths and processing parameters, reducing the time and effort required for manual settings, improving processing efficiency and material utilization. Through path optimization and parameter recommendation, it maximizes processing efficiency, reduces material waste, and enhances processing accuracy. Optimizing path and parameter settings ensures precise cutting and superior processing results. The specific steps are as follows:

[0043] Establish a custom database to store historical processing data, workpiece information, and material properties. The database stores past processing cases, processing experience with different materials, and processing parameters for workpieces of different thicknesses and shapes. This database will serve as the core resource for the system to provide parameter suggestions.

[0044] By matching workpiece parameters with the historical database, the system searches and compares the workpiece information configured by the user, such as material, thickness, machining accuracy and roughness, and automatically selects the most matching machining parameter template in the database, including feed rate and machining accuracy, and recommends suitable machining parameters to the user. If there is no completely matching case in the database, the system provides recommendations for similar parameters and allows users to fine-tune the parameters according to actual needs, so that users can define their desired machining configuration.

[0045] The system analyzes the workpiece graphic and optimizes the corner path. Based on the workpiece graphic drawn by the user, the system combines historical databases, especially at key corner positions, to provide appropriate transition paths. For corners and other complex paths in the workpiece graphic, the system will automatically select appropriate path transition methods to avoid abnormal processing effects at corners. The system will recommend different path smoothing strategies, such as arc transition and straight line transition, to ensure the smoothness and accuracy of processing.

[0046] The system reminds users to adjust path optimization. During the processing, the system reminds users to adjust path or parameter strategies based on the workpiece graphic and the current processing status. The system will analyze the processing path and remind users to adjust the processing strategy at key locations or complex paths based on the current situation. For example, if the path optimization effect is not ideal, the system will prompt users to adjust the smoothness of the transition path or the discharge parameters. The system provides specific adjustment suggestions, and users can choose to accept the suggestions or manually optimize according to actual needs.

[0047] The system provides feedback and optimization suggestions. During the processing, the system monitors the processing quality based on real-time data and provides feedback and optimization suggestions to the user. If problems occur during the processing, the system will provide specific optimization suggestions and remind the user to adjust the path planning or processing parameters. The user can manually adjust the path and parameters based on the feedback and suggestions provided by the system to ensure stable processing quality.

[0048] Furthermore, this system features efficient real-time monitoring and dynamic adjustment. An embedded real-time monitoring module, through integrated data analysis, dynamically optimizes the processing. During processing, the system monitors key parameters in real time, such as discharge intensity and cutting trajectory accuracy. Based on intelligent analysis of the monitoring data, it alerts the user to adjust processing strategies, thereby ensuring processing quality, avoiding defects caused by processing deviations, improving production efficiency, enhancing finished product quality, and reducing the scrap rate. Through precise monitoring and real-time adjustment, the system ensures process stability, reduces errors and defects, ensures process controllability, and minimizes unexpected downtime. Real-time data analysis and feedback make the processing predictable and controllable, reducing the risk of equipment downtime. Specifically, this includes the following steps:

[0049] Data acquisition and real-time monitoring: During the processing, the system collects key parameters in real time through sensors, such as discharge intensity, cutting trajectory accuracy and feed speed. The data is transmitted to the ARM unit, namely AM572x chip, in real time through the communication interface and analyzed. The system continuously monitors and records key parameters to ensure that the data can be viewed and analyzed by users.

[0050] The system controls the discharge intensity by setting an appropriate discharge intensity for each processing section based on the requirements of different processing sections, such as straight sections or turning sections. For areas with high precision requirements, such as corners, the system will automatically reduce the discharge intensity to improve cutting accuracy. For areas where efficiency is the priority, the system will increase the discharge intensity to speed up the cutting speed. The system monitors the discharge intensity in real time, and if a deviation is detected, the user can pause and make manual adjustments.

[0051] Cutting trajectory monitoring and adjustment: The system tracks the actual position of the electrode wire in real time through a high-precision position encoder. The system compares the real-time position with the preset cutting trajectory to detect deviations. If the deviation exceeds the set tolerance range, the system prompts the user to adjust the processing strategy, such as adjusting the feed speed or discharge intensity.

[0052] Historical data recording and continuous improvement: The system automatically records key parameters of each processing step and stores them in the database for users to query. Users can view historical data and evaluate the current processing based on historical processing experience, further optimizing processing parameters and strategies. By analyzing historical data, the system helps users summarize experience and optimize future processing steps.

[0053] For anomaly handling and downtime prevention, the system continuously monitors key parameters during the processing, such as discharge intensity or trajectory accuracy, to ensure timely detection of any anomalies. Once a deviation is detected that exceeds the tolerance range, such as excessive discharge intensity or excessive trajectory deviation, the system will issue an alarm to remind the user to make adjustments. If necessary, the system will pause processing and prompt the user to take corresponding adjustment measures to avoid downtime caused by misoperation or equipment problems.

[0054] Furthermore, automatic taper calibration and compensation addresses the traditional taper machining process, which typically relies on manual trial cuts, calculations, and adjustments—a time-consuming process prone to human error. This system, through innovative automatic taper calibration and compensation technology, completely transforms the traditional taper machining method. The system not only automatically calculates the required machining trajectory based on input parameters but also automatically corrects the distance between the upper and lower guide nozzle surfaces using spark spraying, ensuring the accuracy of the taper machining. This innovation significantly improves the automation and precision of the machining process, reducing manual intervention and calculations. The automatic calculation and correction functions greatly enhance the automation of the taper machining process, reducing human intervention and trial cuts, and significantly improving processing efficiency. By automatically adjusting the distance between the guide nozzles, the system ensures that taper accuracy is unaffected by deviations, thereby improving machining quality. During machining, the system analyzes and optimizes the path in real time, providing feedback and adjustment suggestions to ensure error-free machining and reduce the risk of downtime and quality defects. Due to the introduction of automatic correction and compensation functions, the system can complete high-precision taper machining in a shorter time, saving significant production time. The specific steps are as follows:

[0055] The system automatically calculates the taper machining trajectory. Based on the characteristics of the workpiece and the machining requirements, it can automatically generate an accurate taper machining trajectory that takes into account different taper angles and complex cutting paths of the workpiece, ensuring the accuracy and quality of the machining.

[0056] Automatic taper calibration and compensation: Through advanced sensors and monitoring algorithms, the system monitors the distance between the guide nozzle and the lower guide nozzle in real time and automatically adjusts it according to the actual situation during the processing. Spark correction: When the system detects a distance deviation between the guide nozzles, it will automatically correct it by sparking to fine-tune the distance between the guide nozzles, thereby maintaining taper accuracy. Real-time feedback and correction: During the processing, the system will continuously monitor key parameters to ensure that there is no deviation in the taper processing and immediately compensate for any discrepancies detected.

[0057] The automated process eliminates the need for manual trial cutting. The system completely replaces the manual trial cutting steps in traditional taper machining through calculation and compensation mechanisms. Users only need to input relevant parameters, and the system can automatically calculate and adjust the machining path, eliminating tedious manual operations and calculation processes, thereby reducing the possibility of human error.

[0058] Seamless optimization and processing quality assurance: During the processing, the system continuously optimizes the processing path to ensure that the processing accuracy meets the preset requirements and avoids processing deviations caused by human error. At the same time, the system will also provide feedback based on the processing situation to help users further adjust and optimize the processing strategy to ensure the stability of the final taper processing quality.

[0059] Furthermore, electrode wire compensation can be corrected during processing. In wire electrical discharge machining (EDM), as the electrode wire, such as molybdenum wire, wears down, the actual discharge radius changes. This change directly affects machining accuracy, especially in complex workpieces or high-precision applications, potentially leading to cutting path deviations and impacting machining quality. This system innovatively supports real-time adjustment of electrode wire compensation during processing. Users can manually input a correction value based on the electrode wire's wear condition. The system dynamically adjusts the machining trajectory based on this correction value, ensuring subsequent processing is unaffected by electrode wire wear. This dynamic adjustment allows users to input correction values ​​at any time during processing, flexibly adjusting the compensation based on the degree of electrode wire wear to ensure optimal machining accuracy. The machining path remains precise, improving machining accuracy. By compensating for changes in the discharge radius caused by electrode wire wear in real time, it effectively maintains machining accuracy, making it particularly suitable for high-precision machining tasks. It reduces manual intervention; traditional methods typically require trial cuts and manual adjustments to compensate for electrode wire wear. This technology, however, simplifies the compensation process by inputting correction values ​​in real time, significantly reducing manual intervention and offering convenient operation. Users can input correction values ​​during machining through a simple interface, and the system automatically adjusts the machining trajectory without complex calculations or preset configurations, enhancing flexibility. Users can flexibly adjust correction values ​​according to actual conditions, especially in different machining stages or with different precision requirements, providing more customized options. Specifically, it includes the following steps:

[0060] Real-time correction parameter input: During the processing, users can directly input electrode wire correction values ​​through the operation interface. These values ​​are used to correct changes in the actual discharge radius. Users can manually adjust the processing trajectory by inputting correction values ​​to compensate for changes in the discharge radius caused by electrode wire wear, thereby ensuring that processing accuracy is not affected.

[0061] The system adjusts the machining path in real time. After receiving the correction value input by the user, the system immediately applies the value to the current machining trajectory and dynamically adjusts the machining path. Based on the compensated discharge radius, the system automatically corrects the subsequent cutting path to ensure stable machining accuracy.

[0062] The user interface provides a simple and easy-to-use interface, allowing users to easily input correction values ​​during the processing. Users can monitor the wear of the electrode wire in real time and input correction values ​​based on actual observations. The system provides real-time feedback on the corrected cutting trajectory, ensuring that users can adjust the processing in a timely manner and optimize accuracy.

[0063] The correction value is flexible and adjustable. Users can adjust the correction value according to the needs of different processing stages. For areas with high precision requirements, a larger correction value can be entered to ensure cutting accuracy. Users can adjust the correction value multiple times during processing. Each adjustment will affect the current and subsequent cutting trajectory, ensuring that the precision requirements are met at each stage of the processing.

[0064] Processing feedback and optimization: The system continuously tracks processing accuracy. When deviations occur, users can make real-time corrections by adjusting the correction value. During processing, the system will continue to monitor the processing effect based on the corrected path to ensure the effectiveness of the correction value. If the correction value is insufficient to compensate for excessive wear, the system will prompt the user to make further adjustments.

[0065] Historical records and analysis: The system records each input correction value and the corresponding processing effect for users to query and analyze later. Users can view historical data, analyze the wear trend of electrode wires, and the impact of correction values ​​on processing accuracy, thereby optimizing future processing settings.

[0066] Furthermore, in multi-graphics machining programs, the processing order of each graphic can be flexibly adjusted, allowing for skip-step processing. In traditional multi-graphics machining, the processing order is usually fixed, which can lead to unnecessary path repetition and low processing efficiency when dealing with complex or multi-workpiece machining. This system innovatively introduces skip-step machining technology, allowing users to flexibly adjust the processing order of each graphic in a multi-graphics machining program. In this way, the system can dynamically adjust the order of each processed graphic according to actual needs or processing priorities, thereby optimizing processing time, reducing unnecessary path movements, and improving overall processing efficiency. Skip-step machining technology significantly reduces repeated paths and idle runs by flexibly adjusting the graphic processing order. This technology improves processing efficiency, reduces idle time and waiting time, and skip-step processing avoids unnecessary machine stops on paths, reducing ineffective processing time. It is particularly effective in processing complex graphics and multiple workpieces. It optimizes the process flow, allowing users to adjust the processing sequence according to different process requirements, resulting in a more streamlined process and avoiding processing conflicts caused by sequence issues. It offers greater flexibility and customization, enabling users to adjust the processing sequence according to specific needs without being limited by traditional fixed processes. It also enhances user control, allowing users to dynamically adjust the graphics processing sequence based on processing requirements, process priorities, and other requirements, thus strengthening control over the entire processing process. Specifically, it includes the following steps:

[0067] The processing sequence can be flexibly adjusted. Users can freely set or adjust the processing sequence of each graphic on the system interface. This function allows users to jump between different graphics, avoiding fixed and linear processing flows. By changing the processing sequence of graphics, users can avoid unnecessary path overlap and reduce idle running and downtime during the processing.

[0068] Automatic skipping optimization: The system automatically optimizes the skipping path based on the input processing graphics and sequence. When skipping between multiple graphics, the system uses intelligent algorithms to calculate the optimal skipping path, minimizing blank movement time during processing. Skip processing optimization not only focuses on the processing time of a single graphic, but also comprehensively considers the compactness of the overall processing path to ensure the efficiency of the processing process.

[0069] Processing priority setting allows users to set priorities for different graphics according to actual needs. For example, in the same processing program, some graphics may need to be processed first to meet processing accuracy or other process requirements. The system will determine the processing order according to the priority set by the user. Users can adjust the priority in real time through the interface to ensure that key graphics are processed first.

[0070] The system not only supports adjusting the order of graphics, but also ensures the coordination of paths when jumping between graphics. For example, the system will avoid unnecessary multiple backtracking or switching, ensuring a smoother transition in the processing of each graphics. In step-by-step processing, the system can automatically calculate the jump path according to the processing progress, ensuring the continuity of the processing path and reducing machine downtime.

[0071] User interaction and real-time adjustments: Users can adjust the processing order of graphics at any time during the processing. The system will automatically recalculate the optimal path based on the adjustment. The user interface provides intuitive operation and feedback, and displays the adjusted processing path in real time, ensuring that users can view the processing progress and changes in real time.

[0072] Multi-graphics collaborative processing and skip-step processing support can be used in scenarios involving multi-graphics collaborative processing, especially suitable for complex processing tasks involving large batches and multiple graphics. The system can automatically coordinate the processing sequence of multiple graphics to ensure that the processing of each workpiece is efficient and smooth.

[0073] Furthermore, the rotating coordinate system aims to address the challenge of traditional coordinate systems' inflexibility in complex machining scenarios due to changes in workpiece position or machining requirements. This function allows users to adjust the coordinate system's orientation in real time during machining, rotating the coordinate system to adapt to different workpiece orientations or machining needs, thereby improving machining accuracy and efficiency. The introduction of this technology greatly enhances the system's flexibility and adaptability, particularly in handling complex geometries and special machining path requirements, improving machining accuracy. The rotating coordinate system technology can precisely align the workpiece with the machining path during the machining of complex workpieces, ensuring significantly improved machining accuracy, especially on workpieces with high symmetry requirements or complex geometries. It also reduces manual intervention through dynamic rotation. By rotating the coordinate system, users can quickly adjust the workpiece orientation without manually changing the machining path or program, avoiding tedious reprogramming, improving machining efficiency and adaptability. This technology allows the system to more flexibly adapt to different workpiece postures and machining environments, especially when facing complex or special machining requirements, exhibiting great adaptability and flexibility, accelerating the programming and machining process. Because the rotated coordinate system can be adjusted instantly, it avoids the tedious process of readjusting the coordinate system, path, and machining parameters required in traditional methods, shortening the entire programming and machining cycle. With its intelligent and automated features, the system can automatically adapt to the rotated coordinate system and adjust the machining path without manual intervention, improving the degree of automation in machining, reducing operational errors and adjustment time. Specifically, it includes the following steps:

[0074] The coordinate system rotation function allows users to rotate the machining coordinate system in real time during processing by inputting the rotation angle or coordinate axis, so as to better adapt to the actual posture of the workpiece or the cutting path requirements. The coordinate system rotation can be adjusted based on any axis, X-axis, Y-axis or Z-axis, and the rotation angle can be flexibly set within ±360°, ensuring accurate machining of the workpiece in different orientations.

[0075] Real-time adjustment: During the processing, users can adjust the rotation angle of the coordinate system at any time as needed. This function is especially suitable for quick adjustment when the workpiece position and cutting direction are not ideal during the processing. The change of the rotation coordinate system will be automatically reflected in the processing program. The system calculates and updates the processing path according to the new coordinate system, without the need for manual reprogramming or interruption of the processing process.

[0076] Adaptable to different workpiece postures, the rotating coordinate system technology can flexibly adjust the machining coordinate system according to the specific shape and placement angle of the workpiece. It is particularly suitable for workpieces with complex shapes that cannot be directly machined using the standard coordinate system. For workpieces with irregular angles, users can use the rotating coordinate system to align the coordinate axes with the key features of the workpiece, ensuring accuracy and machining efficiency.

[0077] The machining path is automatically adapted. After the coordinate system is rotated, the system will automatically adjust the calculated machining path to ensure that all movement and machining operations during the machining process are adapted to the new coordinate system. In this way, no matter how the user adjusts the coordinate system, the system will replan the path according to the new coordinate system to avoid machining errors caused by inconsistency in the coordinate system. There is no need for manual intervention or resetting the path. The system will automatically adjust all relevant parameters after rotating the coordinate system to ensure the consistency and accuracy of the machining.

[0078] User interface support: The system provides an intuitive and easy-to-use user interface. Users can view the effect of coordinate system rotation in real time through the graphical interface, adjust the angle and preview the changes immediately. Users can set the rotation angle through sliders, input boxes or buttons, and the interface will provide real-time feedback on the changes to ensure that users can clearly see the effect of rotation and make corresponding adjustments.

[0079] Working in conjunction with other functions, the rotary coordinate system seamlessly collaborates with other machining functions, such as skip machining or discharge intensity control. For example, the rotary coordinate system can be used in conjunction with path optimization or machining sequence in multi-graphic machining to ensure that all machining operations are performed according to the new coordinate system, avoiding conflicts or reduced machining accuracy. After the rotary coordinate system is adjusted, the system will automatically calibrate the path, cutting parameters and machine tool status to ensure the continuity and efficiency of the overall machining process.

[0080] Furthermore, the special handwheel function is a significant innovation, providing a combination of manual and automatic control. This allows operators to achieve greater flexibility and precision in complex machining tasks. Through the handwheel, the system can perform several key operations during machining, such as establishing the workpiece coordinate system, automatic centering, wire breakage shifting, and wire breakage point return. This greatly simplifies the operation process and improves machining efficiency. This technological innovation combines traditional manual operation with intelligent control, enhancing the overall system's automation level and user experience. Flexible operation is achieved through the handwheel, allowing users to control the workpiece positioning and machining progress. When fine adjustments are needed, manual adjustments can be made in real time, while simultaneously enjoying the convenience of automated processing, improving accuracy, and enabling edge and centering. The automatic centering function greatly improves the positioning accuracy during processing, avoids the impact of errors on processing quality, ensures high-precision machining of the workpiece throughout the entire process, and reduces human intervention. The system's automated control, combined with the precise adjustment of the handwheel, allows users to reduce manual intervention when facing complex processing scenarios, improves work efficiency, reduces the risk of misoperation, and reduces downtime. The wire breakage shifting and automatic wire breakage point return functions ensure rapid recovery in the event of wire breakage, reducing downtime and production losses, improving the system's work continuity, and simplifying the operation process. The one-click processing, pause, and stop functions simplify the user's operation process, allowing users to manage the processing process more intuitively and conveniently, reducing learning costs and operational complexity. Specifically, it includes the following steps:

[0081] The edge finding function establishes the workpiece coordinate system. Users can manually operate the equipment to find the edge through the handwheel function, accurately locate the workpiece edge, and thus establish an accurate workpiece coordinate system. The handwheel rotation control system can accurately adjust the relative position of the electrodes according to the user's operation to ensure that the workpiece coordinate system is established accurately and avoid the influence of traditional manual measurement errors. After the edge of the workpiece is determined, the system will automatically record the origin position of the coordinate system to provide accurate reference for subsequent processing.

[0082] The automatic centering function and handwheel function help users quickly center the workpiece, ensuring that the electrode wire remains symmetrical or centered during workpiece processing. The automatic centering function precisely adjusts the relative position of the workpiece and the electrode wire through the operation of the handwheel, ensuring the balance and symmetry of the workpiece during processing and reducing processing errors.

[0083] The centering function allows users to manually "find the center" via the handwheel. This means adjusting the system to precisely locate the center of the workpiece and automatically calibrating the equipment coordinate system. The system automatically calculates and adjusts the processing path by rotating the handwheel, ensuring that the electrode wire is processed at the center of the workpiece. This is suitable for workpieces with symmetrical structures.

[0084] The broken wire shifting and automatic return to the broken wire point functions allow users to manually adjust the shifting axis to ensure the processing can continue if a broken wire occurs during processing. Simultaneously, the system supports automatic return to the broken wire point; when the electrode wire breaks, the handwheel can quickly retract to return the equipment to the broken wire point for continued processing, avoiding wasted time and materials. These functions effectively reduce downtime caused by broken wires, improving the continuity and stability of the processing.

[0085] The one-click processing function is integrated into the handwheel operation. With just one press, the system will automatically start the preset processing flow. The one-click processing function reduces the steps that users need to manually set during operation, automatically starts the processing process, reduces human error and improves work efficiency.

[0086] The pause function allows users to pause processing with a single button press using the handwheel. This function enables users to make necessary adjustments, checks, or handle emergencies during processing. The system automatically saves the current processing status when paused, ensuring that users can accurately continue processing from where they left off after resuming processing, thus avoiding rework and material waste.

[0087] The stop function allows users to immediately halt the machining process by using the handwheel when it is necessary to completely stop the machining operation. The stop function can immediately disconnect the machining process, ensuring the safety of the workpiece, and can be restarted after subsequent processing or adjustments.

[0088] Furthermore, the pitch compensation function aims to solve the pitch deviation problem caused by electrode wire wear and changes in processing parameters during multiple processing steps. By having the user input specific pitch compensation data, the system can correct the pitch based on actual wear or parameter changes, ensuring that the processed thread always meets the preset accuracy requirements. This function significantly improves the accuracy and reliability of thread processing, avoids quality problems caused by pitch errors, and enhances thread processing precision. Through manual input of compensation data, the system can compensate based on electrode wire wear or other factors, ensuring the thread pitch remains accurate. Flexibility and adjustability allow users to flexibly adjust the compensation data according to actual needs, adapting to different workpieces and processing conditions, ensuring that processing accuracy is not affected, and reducing manual intervention. The pitch compensation function reduces the frequency of manual intervention; users only need to input the necessary compensation data, and the system automatically corrects based on this data, simplifying the operation process and improving production efficiency. Through effective compensation, processing rework caused by pitch deviation is avoided, improving overall production efficiency and optimizing the processing process. Users can view and modify compensation data, optimize the processing process based on historical experience, and further improve processing quality and efficiency. Specifically, it includes the following steps:

[0089] Pitch compensation data entry: Before or during processing, users can manually enter pitch compensation data based on the wear of the electrode wire or other influencing factors. This compensation data includes pitch correction values. Users input the corresponding compensation values ​​through the operation interface, and the system will adjust the subsequent processing path based on these data.

[0090] The system uses compensation data. After receiving pitch compensation data, it will adjust the machining parameters, such as feed rate and cutting depth, based on these correction values ​​in subsequent machining. The input of compensation data will directly affect the machining trajectory to ensure that the thread in each section of machining can maintain a precise pitch.

[0091] During the discharge process, the system will adjust the discharge radius between the electrode wire and the workpiece according to the compensation data to ensure that the depth and shape of the thread meet expectations. Users can flexibly input different compensation data to adapt to different workpieces and processing conditions.

[0092] The system allows users to modify and update the pitch compensation value at any time during the machining process based on the actual machining conditions. The system supports modification of the input compensation data to cope with changes in different machining stages and ensure that the pitch always meets the accuracy requirements.

[0093] The system stores and manages compensation data. It stores the compensation data used each time in the database for easy viewing and management by users. Users can query historical data, review previous pitch compensation values, and refer to past experience to optimize the current machining process.

[0094] Manual compensation is supported. If the user finds a pitch deviation during the machining process, the system allows the user to manually adjust the compensation data and reapply it to the machining program to ensure that subsequent thread machining meets the expected standards.

[0095] Furthermore, the user-friendly interface and intelligent guidance, based on modern human-computer interaction design, have developed a graphical and intuitive user interface. The system has a built-in intelligent assistant that provides operation guidance and error diagnosis prompts, supports multi-language and multi-level operation permission settings, adapts to users of different levels, significantly improves the user experience, and is especially friendly to novice users, reducing training costs and operation errors.

[0096] Data integration with proprietary industrial internet platform: The new system supports deep integration with proprietary industrial internet platform, providing users with one-stop data management and analysis functions. The platform enables equipment networking, centrally manages the processing tasks and status monitoring of multiple wire cutting machines, and the data after processing can be automatically uploaded to the platform, supporting process improvement and long-term optimization. Users can remotely view and simply control the equipment status through the platform, but it is not open to third-party systems, providing a unified equipment management and optimization platform, improving the transparency of the production process, and only supporting proprietary platform to ensure high system security and reliability.

[0097] Green and environmentally friendly design minimizes resource waste by optimizing processing technology and operating procedures. Environmental requirements are prioritized during the system design phase, and efficient coolant solutions are used to avoid additional burdens on the environment. This aligns with the green and environmentally friendly concepts of modern manufacturing, simplifies maintenance processes, and enhances the system's sustainability.

[0098] The present invention has the following beneficial effects:

[0099] 1. The planning module can automatically generate production plans. Compared with manual production process arrangement, it has a higher degree of automation and is conducive to improving production efficiency. At the same time, the planning module establishes a general production model, which can automatically optimize the generation logic of subsequent production plans based on manual modification steps, making the production plan arrangement more reasonable.

[0100] 2. The collaborative module automatically records the operating status and calculation responsibilities of each processing unit, enabling intelligent scheduling of processing tasks and graphic calculations, avoiding manual intervention and effectively reducing the investment of human resources.

[0101] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0102] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0103] Figure 1 This is a block diagram of an embedded CNC electrical discharge machining system according to the present invention. Detailed Implementation

[0104] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0105] Please see Figure 1 This invention provides a technical solution: an embedded CNC electrical discharge machining system, comprising a machining unit, a power management unit, a control console, a planning module, and a coordination module. The machining unit includes an ARM unit, a DSP unit, a five-axis motor control module, an HDMI module, an RJ45-HUB, a USB-HUB, an FPGA unit, a handwheel serial port, an RS485 serial port, and an I / O signal processing module. The power management unit includes a protection module and a filtering module. The ports of the control console and the planning module establish communication. The output of the planning module is connected to the input of the coordination module. The output of the ARM unit is connected to the input of the planning module. The connection and coordination module establishes communication with the ARM unit's port; the output of the power management unit is electrically connected to the input of the processing unit; the ARM unit's port establishes communication with the DSP unit, the five-axis motor control module, the RJ45-HUB, the USB-HUB, the FPGA unit, and the RS485 serial port respectively; the DSP unit's port establishes communication with the five-axis motor control module's port; the ARM unit's output is connected to the HDMI module's input; the handwheel serial port's output is connected to the FPGA unit's input; and the IO signal processing module's port establishes communication with the FPGA unit's port.

[0106] The ARM unit is a TIAM572x chip with a Cortex-A15 core architecture, providing powerful computing capabilities suitable for handling high-level control logic, graphical interfaces, and task scheduling functions. The ARM core supports the operation of drawing and machining software, providing users with real-time monitoring, interactive operation interfaces, and display and control of machining paths. The AM572x provides a variety of industrial-grade interfaces, such as SPI, I2C, Ethernet, and UART, which can easily connect to external devices and sensors, supporting efficient data transmission and real-time communication. The main operating system is Linux, which provides an open development environment and a rich software ecosystem for upper-level applications, facilitating development and maintenance. Linux's multi-task scheduling function enables the system to handle multiple tasks simultaneously, such as machining control, path planning, and user interface. The stability and openness of the Linux system allow the system to use mature drawing and path planning software tools, such as CAD and CAM software, to achieve more accurate machining paths and graphic drawing. The system supports multiple storage methods and high-speed data exchange, such as eMMC and SD cards, ensuring the speed and reliability of data storage.

[0107] The FPGA unit, consisting of an FPGA chip, is primarily responsible for controlling the peripheral infrastructure of the handwheel serial port and acquiring signals from the limit I / O signal processing module. Its features and advantages are as follows:

[0108] For peripheral device control, the FPGA unit can directly control external devices, such as motor drives, actuators and sensors, through parallel processing, providing hardware-level control. Compared with software control, the FPGA unit can respond to the needs of external devices more efficiently and with lower latency, ensuring the real-time performance and stability of the system.

[0109] Limit signal acquisition: The FPGA is responsible for acquiring data from external limit switches and sensors, and through real-time hardware processing, it ensures the accurate transmission and response of limit signals. This function is crucial for ensuring equipment safety during the processing.

[0110] Customization and high parallelism: The programmability of FPGA units allows for the customization of control logic according to actual needs, supports multi-channel parallel processing, and enables simultaneous control and signal acquisition of multiple devices, thereby improving the real-time processing capability of the system.

[0111] With low latency and high reliability, the FPGA unit provides low-latency hardware response, ensuring that the system can quickly process external signals, especially in the process of limit signal acquisition and equipment control, which greatly reduces the potential risks caused by latency.

[0112] The DSP unit is a digital signal processing unit responsible for motor data processing and signal transmission of the five-axis motor control module. The DSP is specifically designed to process real-time signals for motor control, ensuring precise adjustment and motion control of the motor to meet high-precision machining requirements. The DSP unit can perform complex mathematical calculations in a very short time, ensuring the accuracy and stability of motor control. Since the DSP is a hardware acceleration unit, it can avoid the latency of traditional processors, ensuring low latency and high-efficiency response of the motor control system.

[0113] The TIAM572x chip + FPGA chip hardware architecture fully leverages the respective advantages of the ARM processor, DSP unit, and FPGA chip, providing the wire EDM system with powerful computing capabilities, flexibility, and real-time response. Based on the AM572x ARM core + DSP + FPGA architecture, the new system maximizes the advantages of each hardware module. The ARM core runs the Linux system and is responsible for high-level control, drawing, and machining tasks; the DSP unit focuses on precise motor control; and the FPGA handles peripheral control and limit signal acquisition. Through this efficient collaborative work, the system not only possesses powerful computing and processing capabilities but also ensures precise control and real-time response, meeting the demands of modern wire EDM systems for efficiency, precision, and stability.

[0114] The RS485 serial port and RJ45-HUB are used to communicate with external sensors or devices, the HDMI module is used to output the graphical interface to the monitor for users to view, and the USB-HUB is used to connect input devices such as keyboards and mice.

[0115] The power management unit is used to supply power to the entire processing unit. The filtering module is used to filter the power input to avoid power instability, and the protection module is used for power overload protection to prevent damage to the processing unit.

[0116] The planning module is used to obtain the production plan and break it down into processing tasks, specifically:

[0117] The planning module obtains the equipment model corresponding to the processing unit from each ARM unit. The planning module breaks down the production plan into several processing tasks according to the equipment model and transmits them to the collaboration module. The collaboration module transmits the processing tasks to the corresponding ARM unit. The processing sequence corresponds one-to-one with each processing unit.

[0118] There are two ways to obtain production plans:

[0119] One method involves the user inputting the production plan via a console and transmitting it to the planning module. The other method involves the planning module retrieving production data from the ARM unit of each processing unit and compiling it into a production plan. Specifically:

[0120] During the production data acquisition phase, the user inputs the part drawings to be processed into the ARM unit using an input device plugged into the USB-HUB. When the processing unit processes the part according to the part drawings, the ARM unit records the production data of the part. The production data includes the processing parameters, processing time, and processing path of the part. The ARM unit uses the MD5 checksum algorithm to verify the production data and obtain the corresponding checksum. The checksum is used to verify the integrity of the production data, prevent changes in the production data, and also prevent parts with similar production data from interfering with each other, thus avoiding data deviations from affecting the generation of the production plan. The ARM unit packages the production data and the corresponding checksum and transmits them to the planning module for storage. The production data serves as historical data of the processing of each part, which can effectively quantify the characteristics of the processing of each part, facilitating data analysis and improving the executability of the production plan.

[0121] During the production data collection phase, the planning module performs cross-simulation based on the production data and the corresponding equipment models of the processing units to obtain a compatibility list and a conflict list. The planning module then categorizes the production data and equipment models according to these lists. It counts the frequency of each production data point and each equipment model in the compatibility list (denoted as JR) and the frequency of each production data point and each equipment model in the conflict list (denoted as CT). When the JR of a production data point or equipment model is greater than its own CT, the planning module places it in the first tier; when the JR of a production data point or equipment model is equal to its own CT, it places it in the second tier; when the JR of a production data point or equipment model is equal to its own CT, it places it in the third tier. When the JR of a particular equipment model is less than its own CT, the planning module will list the production data or equipment model as the third tier. When generating a production plan, the planning module will first obtain production data or equipment models from the third tier for matching. After matching, it will then obtain production data or equipment models from the second tier for matching, and finally obtain production data or equipment models from the first tier for matching. After all production data and equipment models are matched, the production plan is obtained. The production data and equipment models in the first tier have strong compatibility and can be arranged for production more flexibly. However, the production data and equipment models in the third tier are not compatible with each other. Therefore, the third tier, which has weaker applicability, will be arranged for production first, while the first tier, which has greater flexibility, will be arranged for production last.

[0122] It should be noted that each time the planning module obtains production data from any processing unit, it performs a checksum comparison. The checksum corresponding to the newly obtained production data is compared with all the checksums stored in the module. If the checksums match, it means that the newly obtained production data is duplicated, and the newly obtained production data is not recorded. Conversely, if the checksums do not match, it means that the newly obtained production data is not duplicated, and the newly obtained production data is saved. Through the above method, the planning module can realize real-time updates of production data during processing, thereby improving the flexibility of production plan optimization.

[0123] The specific steps for cross-simulation are as follows:

[0124] The planning module will count the number of processing unit equipment models. For each equipment model, a simulation environment will be established. The planning module will perform conditional matching on the production data. Specifically, the production data recorded by the processing unit itself will be matched with the processing units of other equipment models except for its own equipment signals. The matching degree between the production data and the equipment model will be calculated based on the processing size, processing time, and processing path. For example, the processing size height requirement of part A is 120mm, while the maximum processing height of the processing unit of equipment model B is 100mm. The planning module will compare each parameter in the production data in turn to determine whether the production data matches the processing unit of the equipment model. If the match is successful, the planning module will mark the production relationship between the successfully matched production data and the corresponding equipment model as processing compatible. Conversely, if the match is unsuccessful, the planning module will mark the production relationship between the unsuccessfully matched production data and the corresponding equipment model as processing conflict. The planning module will establish a compatibility list and a conflict list. Processing compatible production relationships will be saved to the compatibility list, and processing conflicting production relationships will be saved to the conflict list. Each production data and equipment model has multiple production relationships. Therefore, the applicability of the production data and equipment model can be judged by the number of production relationships.

[0125] The specific steps for breaking down a production plan into processing tasks are as follows:

[0126] The planning module establishes a general production model, which is the RT-X general model. This model automatically breaks down the production plan into processing tasks. By continuously modifying the processing plan, the user's modifications can be used to train the general production model, making the breakdown of processing tasks more and more reasonable. The console retrieves the production plan from the planning module, and the user can directly execute or modify the production plan through the console. When executing the production plan, the general production model merges several production data according to the matching relationship in the production plan to obtain processing tasks and transmits the processing tasks to the designated processing units. The processing tasks are arranged in the order of the third echelon, the second echelon, and the first echelon, making the matching of production data with each processing unit more reasonable. It should be noted that multiple processing units can be of the same equipment model. The number of processing units for each equipment model is determined according to the user's actual processing needs. The ARM in the processing unit processes parts according to the processing tasks.

[0127] When modifying the production plan, users can modify the processing tasks of each processing unit through the console, transfer production data, and adjust the processing order of processing units. Specifically, they can transfer production data between processing units of the same equipment model, adjust the processing order of production data within a processing unit, and adjust the time for different processing units to execute processing tasks.

[0128] If a user modifies the production plan through the console, the planning module records the modification steps. Conversely, if a user executes the production plan directly through the console, the planning module does not record the modification steps. Saving the user's modification steps can serve as a training dataset, facilitating subsequent improvement and optimization of the general production model. After the user makes modifications through the console, the planning module updates the production plan in real time and simulates the operation. The simulation is performed by calculating the processing time required for each production data point and performing a rapid simulation in chronological order. If the planning module detects that there are processing units in the production plan that are idle, it marks the cumulative idle time of that processing unit as a processing void and transmits it to the console for the user to view, thus providing timely reminders. If the planning module does not detect any processing units in the production plan that are idle, it does not perform any operations.

[0129] The console is equipped with a display screen and a keyboard and mouse for input. Users can interact with the console using the keyboard, mouse, and display screen to perform operations such as modifying production plans.

[0130] When all processing units execute processing tasks, the collaboration module obtains the running status and computing load of each ARM unit in real time. The computing load is mainly reflected in the real-time rendering of the ARM unit. The collaboration module has a preset trigger threshold of 95% and a preset saturation threshold of 85%. When the computing load of an ARM unit exceeds the trigger threshold, the collaboration module distributes the computing load of the trigger threshold to the ARM units of other processing units of the same equipment model. The collaboration module calculates the average computing load of ARM units of the same equipment model in real time. When the average computing load exceeds the saturation threshold, the collaboration module distributes the computing load of the trigger saturation threshold to the ARM units of processing units of other equipment models.

[0131] When the ARM unit is in an abnormal operating state, the abnormal operating state includes the processing unit unexpectedly stopping the processing task and the component failure. The coordination module will distribute the unfinished processing tasks of the ARM unit in the abnormal operating state to the ARM units of other processing units of the same equipment model to continue to execute the processing tasks. The ARM unit in the abnormal operating state can continue to share the computing load. The ARM unit reports the abnormal operating state to the planning module. The planning module records the abnormal event and marks the event level as general.

[0132] When two or more ARM units of the same equipment model are in an abnormal operating state, the coordination module will distribute the unfinished processing tasks of the abnormal ARM units to ARM units of other equipment models to continue the processing tasks. The ARM units will report the abnormal operating state to the planning module, and the planning module will record the abnormal event and mark the event level as severe.

[0133] The planning module will then adjust the production plan according to the event level of the abnormal event. Specifically, production data and equipment models with a general event level will be downgraded from the first tier to the second tier or from the second tier to the third tier. No action will be taken if they were originally in the third tier. All production data and equipment models with a severe event level will be included in the third tier. If they were originally in the third tier, the corresponding abnormal event will be output to the console for users to view.

[0134] This system is an integrated design and manufacturing system, realizing the integration of design and manufacturing. It abandons the traditional fragmented model of multiple systems. Users can directly complete graphic design, path planning, and parameter setting within the system without relying on third-party software. Specifically:

[0135] OpenGL accelerates graphics rendering and real-time rendering. X8 and AutoCAD rely on traditional CPU rendering to handle complex graphics and a large number of primitives. As the complexity of graphics increases, the rendering speed may decrease significantly, especially during the visualization of complex designs or large-scale workpieces, resulting in interface lag and operation delays. Although AutoCAD provides graphics rendering acceleration options, it still cannot achieve the performance of efficiently handling complex models and large graphics. Especially when the number of graphics increases sharply, rendering and interface responsiveness will be affected. The new system introduces OpenGL to accelerate graphics rendering, using the hardware acceleration capabilities of the GPU to render graphics in real time, solving the performance bottleneck in the traditional CPU rendering solution. When processing complex or large numbers of graphics, the system can maintain a rendering speed of more than 30 FPS. Even when processing complex 3D workpieces, it can still maintain a smooth operating interface. OpenGL technology, through hardware acceleration rendering, not only reduces the CPU's computational burden, but also optimizes the rendering process of frustum culling, rasterization, and texture mapping, so that even when there are many graphics, it can still maintain a high frame rate and high response speed, greatly improving the user's interactive experience.

[0136] The RTree primitive lookup algorithm and optimized object snapping: While AutoCAD and X8 offer basic object snapping functionality, they still suffer from performance bottlenecks when searching for a large number of graphics in complex scenes. When the number of graphics is excessive, the response speed of the snapping operation often decreases, resulting in a poor user experience, especially during intensive primitive searches where delays may occur. The new system introduces the RTree primitive lookup algorithm, which optimizes the efficiency of graphic search by spatial indexing and partitioning primitives. Particularly in complex workpiece design, it enables fast and accurate object snapping. This algorithm utilizes an R-tree data structure for spatial indexing of primitives, reducing unnecessary search calculations and accurately locating target objects, significantly improving the speed and accuracy of object snapping. RTree reduces the complexity of query operations by dynamically balancing the tree structure, enabling rapid response when processing a large number of graphics without interface lag or operational delays. This greatly improves work efficiency for users who need to efficiently snap and manipulate large numbers of graphics.

[0137] While AutoCAD and X8 support basic path planning, they are mostly used for 2D or simple 3D path design. For scenarios requiring multi-tool cutting or complex machining, traditional software usually requires users to manually divide the path or cannot automatically generate multi-tool cutting paths. The new system, through its path generation and multi-tool trajectory optimization function, can automatically decompose the machining path into trajectories suitable for multi-tool cutting and export standard G / 3B code. Through intelligent path decomposition, the system can automatically determine which paths are suitable for multi-tool cutting and generate corresponding cutting trajectories according to specific requirements. This greatly improves the efficiency and accuracy of CNC machining, especially for workpieces that require staged or complex path cutting. Compared with the manual path design of traditional software, the system can automatically optimize the cutting path, reduce manual intervention, improve machining accuracy, and shorten machining time. The multi-tool trajectory generation and code output functions seamlessly connect with the machining process of CNC machine tools, reducing the production cycle of workpieces and errors in manual operation.

[0138] For drawing and generating unconventional quadratic curves, AutoCAD and X8 support drawing some basic standard curves, such as circles or straight lines. However, for complex quadratic curves such as ellipses, gears, and spline curves, manual drawing or plugins are usually required. Moreover, these software programs do not directly support generating corresponding machining codes and usually require other external tools. The new system supports drawing and generating unconventional quadratic curves such as ellipses, gears, and spline curves. The system has a built-in high-precision curve drawing algorithm that can automatically generate corresponding G / 3B codes to meet high-precision machining requirements. For drawing and generating codes for complex shapes, the system adopts mathematical modeling and precise calculation methods, avoiding the tediousness of traditional manual drawing or external plugins. The system processes these curves automatically, thereby significantly improving design efficiency and machining accuracy.

[0139] The new system features intelligent parsing and syntax checking of G / 3B code. While AutoCAD and X8 typically provide basic code generation for G-code output, they lack built-in intelligent parsing or syntax checking capabilities. Users may need to rely on external tools or manually verify the code's correctness, which can easily lead to errors, especially in the machining of complex workpieces. Incorrect code can cause machining failures or material waste. The new system features intelligent parsing, editing, and syntax checking of G / 3B code. The system can automatically analyze the generated code, detect potential syntax and path errors, and provide correction suggestions. This effectively avoids machining problems caused by non-standard code, improving system stability and reliability. The intelligent parsing function can automatically identify and repair erroneous code in real time, reducing the time spent on manual inspection and correction, greatly improving work efficiency, and reducing the risk of machining failures, ensuring safety and accuracy during the machining process.

[0140] The XYUV 4-axis linkage algorithm and multi-dimensional path control: AutoCAD and X8 path planning are usually based on two-dimensional or simple three-dimensional paths, which are difficult to directly support complex multi-axis linkage. For complex paths such as vertical, tapered, and irregularly shaped paths, special post-processing tools or plugins are usually required to optimize and adjust the path. The new system introduces the XYUV 4-axis linkage algorithm, which supports multi-dimensional path control for complex paths, such as vertical, tapered, and irregularly shaped paths. Through precise multi-axis linkage, the system can control multiple motor axes simultaneously during the machining process, making the path more flexible and accurate. It is particularly suitable for high-precision machining. The algorithm can control the movement of multiple axes at the same time, ensuring the accuracy and stability of the machining path. Especially when dealing with complex geometry, the system can adaptively adjust the path, optimize the machining route, and reduce errors and machining time.

[0141] The new system utilizes OpenGL technology to achieve 3D workpiece trajectory visualization and real-time machining status display. AutoCAD and X8's graphical visualization is typically limited to static displays and does not support real-time tracking of dynamic changes in the workpiece during machining. Users cannot directly see the real-time status of the machining process on the software interface and usually rely on external display devices to obtain real-time data. Users can see the entire machining process through a 3D display, including real-time motor positions and machining paths. This real-time dynamic feedback allows users to adjust or correct the path at any time during machining, improving operational flexibility and accuracy. This function enhances the transparency and control of the production process, enabling users to intuitively understand the machining status and make timely adjustments to ensure coordination between machining accuracy and progress.

[0142] Among its features, manual path optimization and parameter recommendation are offered by the system. Based on its built-in rule base and processing experience, the system provides path optimization suggestions and parameter recommendations. By analyzing the workpiece graphics drawn by the user and combining them with historical data, the system provides intelligent cutting path planning and processing parameter recommendations. Especially when dealing with different materials, thicknesses, and shapes, the system can automatically recommend the most suitable cutting path and processing settings, greatly improving processing efficiency and material utilization while simplifying the user's operation process. The specific steps are as follows:

[0143] Establish a custom database to store historical processing data, workpiece information, and material properties. The database stores past processing cases, processing experience with different materials, and processing parameters for workpieces of different thicknesses and shapes. This database will serve as the core resource for the system to provide parameter suggestions.

[0144] By matching workpiece parameters with the historical database, the system searches and compares the workpiece information configured by the user, such as material, thickness, machining accuracy and roughness, and automatically selects the most matching machining parameter template in the database, including feed rate and machining accuracy, and recommends suitable machining parameters to the user. If there is no completely matching case in the database, the system provides recommendations for similar parameters and allows users to fine-tune the parameters according to actual needs, so that users can define their desired machining configuration.

[0145] The system analyzes the workpiece graphic and optimizes the corner path. Based on the workpiece graphic drawn by the user, the system combines historical databases, especially at key corner positions, to provide appropriate transition paths. For corners and other complex paths in the workpiece graphic, the system will automatically select appropriate path transition methods to avoid abnormal processing effects at corners. The system will recommend different path smoothing strategies, such as arc transition and straight line transition, to ensure the smoothness and accuracy of processing.

[0146] The system reminds users to adjust path optimization. During the processing, the system reminds users to adjust path or parameter strategies based on the workpiece graphic and the current processing status. The system will analyze the processing path and remind users to adjust the processing strategy at key locations or complex paths based on the current situation. For example, if the path optimization effect is not ideal, the system will prompt users to adjust the smoothness of the transition path or the discharge parameters. The system provides specific adjustment suggestions, and users can choose to accept the suggestions or manually optimize according to actual needs.

[0147] The system provides feedback and optimization suggestions. During the processing, the system monitors the processing quality based on real-time data and provides feedback and optimization suggestions to the user. If problems occur during the processing, the system will provide specific optimization suggestions and remind the user to adjust the path planning or processing parameters. The user can manually adjust the path and parameters based on the feedback and suggestions provided by the system to ensure stable processing quality.

[0148] Among its features, efficient real-time monitoring and dynamic adjustment are achieved through an embedded real-time monitoring module. This module utilizes integrated data analysis to dynamically optimize the processing. During processing, the system monitors key parameters such as discharge intensity and cutting trajectory accuracy in real time. Based on the monitoring data, it intelligently analyzes the data and alerts the user to adjust the processing strategy, thereby ensuring processing quality, avoiding defects caused by processing deviations, and improving production efficiency. Specifically, this includes the following steps:

[0149] Data acquisition and real-time monitoring: During the processing, the system collects key parameters in real time through sensors, such as discharge intensity, cutting trajectory accuracy and feed speed. The data is transmitted to the ARM unit, namely AM572x chip, in real time through the communication interface and analyzed. The system continuously monitors and records key parameters to ensure that the data can be viewed and analyzed by users.

[0150] The system controls the discharge intensity by setting an appropriate discharge intensity for each processing section based on the requirements of different processing sections, such as straight sections or turning sections. For areas with high precision requirements, such as corners, the system will automatically reduce the discharge intensity to improve cutting accuracy. For areas where efficiency is the priority, the system will increase the discharge intensity to speed up the cutting speed. The system monitors the discharge intensity in real time, and if a deviation is detected, the user can pause and make manual adjustments.

[0151] Cutting trajectory monitoring and adjustment: The system tracks the actual position of the electrode wire in real time through a high-precision position encoder. The system compares the real-time position with the preset cutting trajectory to detect deviations. If the deviation exceeds the set tolerance range, the system prompts the user to adjust the processing strategy, such as adjusting the feed speed or discharge intensity.

[0152] Historical data recording and continuous improvement: The system automatically records key parameters of each processing step and stores them in the database for users to query. Users can view historical data and evaluate the current processing based on historical processing experience, further optimizing processing parameters and strategies. By analyzing historical data, the system helps users summarize experience and optimize future processing steps.

[0153] For anomaly handling and downtime prevention, the system continuously monitors key parameters during the processing, such as discharge intensity or trajectory accuracy, to ensure timely detection of any anomalies. Once a deviation is detected that exceeds the tolerance range, such as excessive discharge intensity or excessive trajectory deviation, the system will issue an alarm to remind the user to make adjustments. If necessary, the system will pause processing and prompt the user to take corresponding adjustment measures to avoid downtime caused by misoperation or equipment problems.

[0154] Among these features, automatic taper calibration and compensation addresses the traditional taper machining process, which typically relies on manual trial cutting, calculation, and adjustment—a time-consuming process prone to human error. This system addresses this issue with innovative automatic taper calibration and compensation technology, fundamentally changing the traditional taper machining method. The system not only automatically calculates the required machining trajectory based on input parameters but also automatically corrects the distance between the upper and lower guide nozzle surfaces using spark jetting, ensuring the accuracy of taper machining. This innovation significantly improves the automation and precision of machining while reducing manual intervention and calculation work. The specific steps are as follows:

[0155] The system automatically calculates the taper machining trajectory. Based on the characteristics of the workpiece and the machining requirements, it can automatically generate an accurate taper machining trajectory that takes into account different taper angles and complex cutting paths of the workpiece, ensuring the accuracy and quality of the machining.

[0156] Automatic taper calibration and compensation: Through advanced sensors and monitoring algorithms, the system monitors the distance between the guide nozzle and the lower guide nozzle in real time and automatically adjusts it according to the actual situation during the processing. Spark correction: When the system detects a distance deviation between the guide nozzles, it will automatically correct it by sparking to fine-tune the distance between the guide nozzles, thereby maintaining taper accuracy. Real-time feedback and correction: During the processing, the system will continuously monitor key parameters to ensure that there is no deviation in the taper processing and immediately compensate for any discrepancies detected.

[0157] The automated process eliminates the need for manual trial cutting. The system completely replaces the manual trial cutting steps in traditional taper machining through calculation and compensation mechanisms. Users only need to input relevant parameters, and the system can automatically calculate and adjust the machining path, eliminating tedious manual operations and calculation processes, thereby reducing the possibility of human error.

[0158] Seamless optimization and processing quality assurance: During the processing, the system continuously optimizes the processing path to ensure that the processing accuracy meets the preset requirements and avoids processing deviations caused by human error. At the same time, the system will also provide feedback based on the processing situation to help users further adjust and optimize the processing strategy to ensure the stability of the final taper processing quality.

[0159] The system features a real-time electrode wire compensation adjustment feature. In wire electrical discharge machining (EDM), the electrode wire, such as molybdenum wire, gradually wears down with use, causing a change in the actual discharge radius. This change directly affects machining accuracy, especially for complex workpieces or high-precision applications, potentially leading to cutting path deviations and impacting machining quality. This system innovatively supports real-time adjustment of electrode wire compensation during machining. Users can manually input a correction value based on the electrode wire's wear condition, and the system dynamically adjusts the machining trajectory accordingly to ensure subsequent machining is unaffected by electrode wire wear. The specific steps include:

[0160] Real-time correction parameter input: During the processing, users can directly input electrode wire correction values ​​through the operation interface. These values ​​are used to correct changes in the actual discharge radius. Users can manually adjust the processing trajectory by inputting correction values ​​to compensate for changes in the discharge radius caused by electrode wire wear, thereby ensuring that processing accuracy is not affected.

[0161] The system adjusts the machining path in real time. After receiving the correction value input by the user, the system immediately applies the value to the current machining trajectory and dynamically adjusts the machining path. Based on the compensated discharge radius, the system automatically corrects the subsequent cutting path to ensure stable machining accuracy.

[0162] The user interface provides a simple and easy-to-use interface, allowing users to easily input correction values ​​during the processing. Users can monitor the wear of the electrode wire in real time and input correction values ​​based on actual observations. The system provides real-time feedback on the corrected cutting trajectory, ensuring that users can adjust the processing in a timely manner and optimize accuracy.

[0163] The correction value is flexible and adjustable. Users can adjust the correction value according to the needs of different processing stages. For areas with high precision requirements, a larger correction value can be entered to ensure cutting accuracy. Users can adjust the correction value multiple times during processing. Each adjustment will affect the current and subsequent cutting trajectory, ensuring that the precision requirements are met at each stage of the processing.

[0164] Processing feedback and optimization: The system continuously tracks processing accuracy. When deviations occur, users can make real-time corrections by adjusting the correction value. During processing, the system will continue to monitor the processing effect based on the corrected path to ensure the effectiveness of the correction value. If the correction value is insufficient to compensate for excessive wear, the system will prompt the user to make further adjustments.

[0165] Historical records and analysis: The system records each input correction value and the corresponding processing effect for users to query and analyze later. Users can view historical data, analyze the wear trend of electrode wires, and the impact of correction values ​​on processing accuracy, thereby optimizing future processing settings.

[0166] In multi-graphics machining programs, the processing order of each graphic can be flexibly adjusted, allowing for skip-step processing. In traditional multi-graphics machining, the processing order is usually fixed, which can lead to unnecessary path repetition and low processing efficiency when dealing with complex or multi-workpiece machining. This system innovatively introduces skip-step processing technology, allowing users to flexibly adjust the processing order of each graphic in a multi-graphics machining program. In this way, the system can dynamically adjust the order of each processed graphic according to actual needs or processing priorities, thereby optimizing processing time, reducing unnecessary path movements, and improving overall processing efficiency. Specifically, it includes the following steps:

[0167] The processing sequence can be flexibly adjusted. Users can freely set or adjust the processing sequence of each graphic on the system interface. This function allows users to jump between different graphics, avoiding fixed and linear processing flows. By changing the processing sequence of graphics, users can avoid unnecessary path overlap and reduce idle running and downtime during the processing.

[0168] Automatic skipping optimization: The system automatically optimizes the skipping path based on the input processing graphics and sequence. When skipping between multiple graphics, the system uses intelligent algorithms to calculate the optimal skipping path, minimizing blank movement time during processing. Skip processing optimization not only focuses on the processing time of a single graphic, but also comprehensively considers the compactness of the overall processing path to ensure the efficiency of the processing process.

[0169] Processing priority setting allows users to set priorities for different graphics according to actual needs. For example, in the same processing program, some graphics may need to be processed first to meet processing accuracy or other process requirements. The system will determine the processing order according to the priority set by the user. Users can adjust the priority in real time through the interface to ensure that key graphics are processed first.

[0170] The system not only supports adjusting the order of graphics, but also ensures the coordination of paths when jumping between graphics. For example, the system will avoid unnecessary multiple backtracking or switching, ensuring a smoother transition in the processing of each graphics. In step-by-step processing, the system can automatically calculate the jump path according to the processing progress, ensuring the continuity of the processing path and reducing machine downtime.

[0171] User interaction and real-time adjustments: Users can adjust the processing order of graphics at any time during the processing. The system will automatically recalculate the optimal path based on the adjustment. The user interface provides intuitive operation and feedback, and displays the adjusted processing path in real time, ensuring that users can view the processing progress and changes in real time.

[0172] Multi-graphics collaborative processing and skip-step processing support can be used in scenarios involving multi-graphics collaborative processing, especially suitable for complex processing tasks involving large batches and multiple graphics. The system can automatically coordinate the processing sequence of multiple graphics to ensure that the processing of each workpiece is efficient and smooth.

[0173] Among them, the rotating coordinate system aims to address the challenge of traditional coordinate systems' inflexibility in complex machining scenarios due to changes in workpiece position or machining requirements. This function allows users to adjust the coordinate system's orientation in real time during machining, rotating the coordinate system to adapt to different workpiece orientations or machining needs, thereby improving machining accuracy and efficiency. The introduction of this technology greatly enhances the system's flexibility and adaptability, especially in handling complex geometries and special machining path requirements. Specifically, it includes the following steps:

[0174] The coordinate system rotation function allows users to rotate the machining coordinate system in real time during processing by inputting the rotation angle or coordinate axis, so as to better adapt to the actual posture of the workpiece or the cutting path requirements. The coordinate system rotation can be adjusted based on any axis, X-axis, Y-axis or Z-axis, and the rotation angle can be flexibly set within ±360°, ensuring accurate machining of the workpiece in different orientations.

[0175] Real-time adjustment: During the processing, users can adjust the rotation angle of the coordinate system at any time as needed. This function is especially suitable for quick adjustment when the workpiece position and cutting direction are not ideal during the processing. The change of the rotation coordinate system will be automatically reflected in the processing program. The system calculates and updates the processing path according to the new coordinate system, without the need for manual reprogramming or interruption of the processing process.

[0176] Adaptable to different workpiece postures, the rotating coordinate system technology can flexibly adjust the machining coordinate system according to the specific shape and placement angle of the workpiece. It is particularly suitable for workpieces with complex shapes that cannot be directly machined using the standard coordinate system. For workpieces with irregular angles, users can use the rotating coordinate system to align the coordinate axes with the key features of the workpiece, ensuring accuracy and machining efficiency.

[0177] The machining path is automatically adapted. After the coordinate system is rotated, the system will automatically adjust the calculated machining path to ensure that all movement and machining operations during the machining process are adapted to the new coordinate system. In this way, no matter how the user adjusts the coordinate system, the system will replan the path according to the new coordinate system to avoid machining errors caused by inconsistency in the coordinate system. There is no need for manual intervention or resetting the path. The system will automatically adjust all relevant parameters after rotating the coordinate system to ensure the consistency and accuracy of the machining.

[0178] User interface support: The system provides an intuitive and easy-to-use user interface. Users can view the effect of coordinate system rotation in real time through the graphical interface, adjust the angle and preview the changes immediately. Users can set the rotation angle through sliders, input boxes or buttons, and the interface will provide real-time feedback on the changes to ensure that users can clearly see the effect of rotation and make corresponding adjustments.

[0179] Working in conjunction with other functions, the rotary coordinate system seamlessly collaborates with other machining functions, such as skip machining or discharge intensity control. For example, the rotary coordinate system can be used in conjunction with path optimization or machining sequence in multi-graphic machining to ensure that all machining operations are performed according to the new coordinate system, avoiding conflicts or reduced machining accuracy. After the rotary coordinate system is adjusted, the system will automatically calibrate the path, cutting parameters and machine tool status to ensure the continuity and efficiency of the overall machining process.

[0180] Among these innovations, the special handwheel function is a significant innovation. It provides a combination of manual and automatic control, enabling operators to achieve greater flexibility and precision in complex machining tasks. Through the handwheel, the system can perform several key operations during machining, such as establishing the workpiece coordinate system, automatic centering, wire breakage correction, and wire breakage point return. This greatly simplifies the operation process and improves machining efficiency. This technological innovation combines traditional manual operation with intelligent control, enhancing the overall system's automation level and user experience. Specifically, it includes the following steps:

[0181] The edge finding function establishes the workpiece coordinate system. Users can manually operate the equipment to find the edge through the handwheel function, accurately locate the workpiece edge, and thus establish an accurate workpiece coordinate system. The handwheel rotation control system can accurately adjust the relative position of the electrodes according to the user's operation to ensure that the workpiece coordinate system is established accurately and avoid the influence of traditional manual measurement errors. After the edge of the workpiece is determined, the system will automatically record the origin position of the coordinate system to provide accurate reference for subsequent processing.

[0182] The automatic centering function and handwheel function help users quickly center the workpiece, ensuring that the electrode wire remains symmetrical or centered during workpiece processing. The automatic centering function precisely adjusts the relative position of the workpiece and the electrode wire through the operation of the handwheel, ensuring the balance and symmetry of the workpiece during processing and reducing processing errors.

[0183] The centering function allows users to manually "find the center" via the handwheel. This means adjusting the system to precisely locate the center of the workpiece and automatically calibrating the equipment coordinate system. The system automatically calculates and adjusts the processing path by rotating the handwheel, ensuring that the electrode wire is processed at the center of the workpiece. This is suitable for workpieces with symmetrical structures.

[0184] The broken wire shifting and automatic return to the broken wire point functions allow users to manually adjust the shifting axis to ensure the processing can continue if a broken wire occurs during processing. Simultaneously, the system supports automatic return to the broken wire point; when the electrode wire breaks, the handwheel can quickly retract to return the equipment to the broken wire point for continued processing, avoiding wasted time and materials. These functions effectively reduce downtime caused by broken wires, improving the continuity and stability of the processing.

[0185] The one-click processing function is integrated into the handwheel operation. With just one press, the system will automatically start the preset processing flow. The one-click processing function reduces the steps that users need to manually set during operation, automatically starts the processing process, reduces human error and improves work efficiency.

[0186] The pause function allows users to pause processing with a single button press using the handwheel. This function enables users to make necessary adjustments, checks, or handle emergencies during processing. The system automatically saves the current processing status when paused, ensuring that users can accurately continue processing from where they left off after resuming processing, thus avoiding rework and material waste.

[0187] The stop function allows users to immediately halt the machining process by using the handwheel when it is necessary to completely stop the machining operation. The stop function can immediately disconnect the machining process, ensuring the safety of the workpiece, and can be restarted after subsequent processing or adjustments.

[0188] The pitch compensation function aims to solve the pitch deviation problem caused by electrode wire wear and changes in processing parameters during multiple processing steps. By having the user input specific pitch compensation data, the system can correct the pitch based on the actual wear or parameter changes, ensuring that the processed thread always meets the preset accuracy requirements. This function significantly improves the accuracy and reliability of thread processing and avoids quality problems caused by pitch errors. Specifically, it includes the following steps:

[0189] Pitch compensation data entry: Before or during processing, users can manually enter pitch compensation data based on the wear of the electrode wire or other influencing factors. This compensation data includes pitch correction values. Users input the corresponding compensation values ​​through the operation interface, and the system will adjust the subsequent processing path based on these data.

[0190] The system uses compensation data. After receiving pitch compensation data, it will adjust the machining parameters, such as feed rate and cutting depth, based on these correction values ​​in subsequent machining. The input of compensation data will directly affect the machining trajectory to ensure that the thread in each section of machining can maintain a precise pitch.

[0191] During the discharge process, the system will adjust the discharge radius between the electrode wire and the workpiece according to the compensation data to ensure that the depth and shape of the thread meet expectations. Users can flexibly input different compensation data to adapt to different workpieces and processing conditions.

[0192] The system allows users to modify and update the pitch compensation value at any time during the machining process based on the actual machining conditions. The system supports modification of the input compensation data to cope with changes in different machining stages and ensure that the pitch always meets the accuracy requirements.

[0193] The system stores and manages compensation data. It stores the compensation data used each time in the database for easy viewing and management by users. Users can query historical data, review previous pitch compensation values, and refer to past experience to optimize the current machining process.

[0194] Manual compensation is supported. If the user finds a pitch deviation during the machining process, the system allows the user to manually adjust the compensation data and reapply it to the machining program to ensure that subsequent thread machining meets the expected standards.

[0195] Among them, the user-friendly interface and intelligent guidance are based on modern human-computer interaction design, and a graphical and intuitive user interface has been developed. The system has a built-in intelligent assistant that provides operation guidance and error diagnosis prompts, supports multi-language and multi-level operation permission settings, and is suitable for users of different levels.

[0196] Data integration with proprietary industrial internet platform: The new system supports deep integration with proprietary industrial internet platform, providing users with one-stop data management and analysis functions. The platform enables equipment networking, centrally manages the processing tasks and status monitoring of multiple wire cutting machines, and the data after processing can be automatically uploaded to the platform, supporting process improvement and long-term optimization. Users can remotely view and simply control the equipment status through the platform, but it is not open to third-party systems.

[0197] The green and environmentally friendly design minimizes resource waste by optimizing processing technology and operation procedures. Environmental protection requirements are given priority in the system design phase, and a high-efficiency coolant solution is used to avoid additional burden on the environment.

[0198] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An embedded CNC electrical discharge machining system, comprising a machining unit, a power management unit, a control console, a planning module, and a coordination module, characterized in that: The processing unit includes an ARM unit, a DSP unit, a five-axis motor control module, an HDMI module, an RJ45-HUB, a USB-HUB, an FPGA unit, a handwheel serial port, an RS485 serial port, and an IO signal processing module. The power management unit includes a protection module and a filtering module. The port of the control console communicates with the port of the planning module. The output of the planning module is connected to the input of the coordination module. The output of the ARM unit is connected to the input of the planning module. The port of the coordination module communicates with the port of the ARM unit. The output of the power management unit is electrically connected to the input of the processing unit. The ports of the ARM unit communicate with the ports of the DSP unit, the five-axis motor control module, the RJ45-HUB, the USB-HUB, the FPGA unit, and the RS485 serial port. The port of the DSP unit communicates with the port of the five-axis motor control module. The output of the ARM unit is connected to the input of the HDMI module. The output of the handwheel serial port is connected to the input of the FPGA unit. The port of the IO signal processing module communicates with the port of the FPGA unit. The ARM unit is used to process high-level control logic, graphical interface and task scheduling to support the operation of drawing and machining software, and provides real-time monitoring, interactive operation interface and display and control of machining path; The planning module is used to obtain the production plan and break it down into processing tasks, specifically: The planning module obtains the processing unit equipment model from each ARM unit, breaks down the production plan into several processing tasks, and transmits them to the collaboration module, which then transmits the processing tasks to the ARM unit. There are two ways to obtain production plans: One method involves the user inputting the production plan through the console and transmitting it to the planning module; the other method involves the planning module acquiring production data from each ARM unit and compiling it into a production plan, specifically consisting of a production data acquisition stage and a production data aggregation stage. During the production data acquisition phase, the user inputs part drawings into the ARM unit using an input device. When the processing unit processes the part according to the part drawings, the ARM unit records the production data of the part. The production data includes the processing parameters, processing time and processing path of the part. The ARM unit uses the MD5 check algorithm to check the production data to obtain the check code. The ARM unit packages the production data and check code and transmits them to the planning module for storage. During the production data collection phase, the planning module performs cross-simulation based on the production data and equipment models to obtain a compatibility list and a conflict list. When all processing units execute processing tasks, the collaboration module obtains the running status and computing load of each ARM unit in real time. The collaboration module presets a trigger threshold and a saturation threshold. When the computing load exceeds the trigger threshold, the computing load of the trigger threshold is distributed to other ARM units of the same device model. The average computing load of ARM units of the same device model is calculated in real time. When the average computing load exceeds the saturation threshold, the computing load of the trigger saturation threshold is distributed to ARM units of other device models.

2. The embedded CNC electrical discharge machining system according to claim 1, characterized in that, Each time the planning module obtains production data from any processing unit, it performs a checksum comparison. If the checksums match, the production data is not recorded; otherwise, if the checksums do not match, it means that the newly obtained production data is not duplicated, and the production data is saved.

3. The embedded CNC electrical discharge machining system according to claim 1, characterized in that, The specific steps for cross-simulation are as follows: The planning module will count the number of processing unit equipment models. For each equipment model, a simulation environment will be established. The production data will be matched conditionally. Specifically, the production data of the processing unit will be matched with the processing units of other equipment models. The degree of matching between the production data and the equipment model will be calculated based on the processing size, processing time and processing path. If the matching is successful, the production data and the production relationship of the successfully matched equipment model will be marked as processing compatible. Otherwise, if the matching is unsuccessful, the production data and the production relationship of the unsuccessful matched equipment model will be marked as processing conflict. A compatibility list and a conflict list will be established. Processing compatible production relationships will be saved to the compatibility list, and processing conflicting production relationships will be saved to the conflict list.

4. The embedded CNC electrical discharge machining system according to claim 1, characterized in that, The specific steps for breaking down a production plan into processing tasks are as follows: The planning module establishes a general production model, and the console obtains the production plan from the planning module. Users can directly execute or modify the production plan through the console. When executing the production plan, the general production model integrates several production data to obtain processing tasks and transmits the processing tasks to the designated processing unit. The ARM in the processing unit processes the parts according to the processing tasks. When modifying the production plan, users can modify the processing tasks of each processing unit through the console, transfer production data, and adjust the processing order of processing units. Specifically, they can transfer production data between processing units of the same equipment model, adjust the processing order of production data within a processing unit, and adjust the time for different processing units to execute processing tasks. If a user modifies the production plan through the console, the planning module records the modification steps. Conversely, if a user executes the production plan directly through the console, the planning module does not record it. After the user makes modifications using the console, the production plan is updated in real time and simulated. The simulation is performed quickly by calculating the processing time of each production data point in chronological order. If a processing unit is found to be idle in the production plan, the cumulative idle time of that processing unit is marked as a processing void and transmitted to the console for the user to view. If no processing unit is found to be idle in the production plan, no operation is performed.

5. An embedded CNC electrical discharge machining system according to claim 1, characterized in that, When the ARM unit is in an abnormal operating state, the coordination module will distribute the unfinished processing tasks of the ARM unit to other ARM units of the same equipment model to continue to execute the processing tasks. The ARM unit in an abnormal operating state can continue to share the computing load. The ARM unit will report the abnormal operating state to the planning module, record the abnormal event and mark the event level as general. When two or more ARM units of the same equipment model are in an abnormal running status, the unfinished processing tasks of the ARM units are distributed to ARM units of other equipment models to continue the processing tasks. The ARM units report the abnormal running status to the planning module, record the abnormal event and mark the event level as severe. The planning module will subsequently adjust the production plan based on the event severity of the abnormal event.

6. An embedded CNC electrical discharge machining system according to claim 1, characterized in that, The planning module categorizes production data and equipment models, counts the frequency of each production data and equipment model in the compatibility list (marked as JR), and counts the frequency of each production data and equipment model in the conflict list (CT). When the JR of a production data or equipment model is greater than CT, it is placed in the first tier; when the JR is equal to CT, it is placed in the second tier; and when the JR is less than CT, it is placed in the third tier. When generating a production plan, production data or equipment models are first retrieved from the third tier for matching. After matching, production data or equipment models are retrieved from the second tier for matching, and finally from the first tier for matching. The production plan is obtained after all production data and equipment models have been matched.

7. An embedded CNC electrical discharge machining system according to claim 1, characterized in that, The RS485 serial port and RJ45-HUB are used to communicate with external sensors or devices, the HDMI module is used to output a graphical interface, and the USB-HUB is used to connect input devices such as keyboards and mice. The power management unit supplies power to the entire processing unit, with a filtering module for power input filtering and a protection module for power overload protection.

8. An embedded CNC electrical discharge machining system according to claim 1, characterized in that, The FPGA unit is an FPGA chip responsible for the control of the handwheel serial port and the IO signal processing module; The DSP unit is a digital signal processing unit responsible for motor data processing and signal transmission for the five-axis motor control module.

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