Online detection method and detection device for discharge cutting

Abstract

The invention relates to the field of discharge cutting online detection, in particular to an online detection method and device for discharge cutting. The device comprises a discharge cutting machine tool and an experiment detection platform, the method comprises the steps that a machined workpiece is machined on a discharge cutting machine tool in a fixed-distance segmented machining mode; after the machining section is completed, the clamping mechanism for clamping the machined workpiece is integrally moved to the experiment detection platform; detecting and recording the current processing section on the processing workpiece through the experimental detection platform; with the current machining section as a starting point, fixed-distance machining of the next section is conducted again; detecting and recording the processing workpiece of the current fixed-distance processing section; and the process is finished. Through a fixed-distance multi-section cutting machining mode, the workpiece can be effectively detected in the machining process, the workpiece is freely switched between machining equipment and detection along with the clamp, the detection efficiency is improved, and the technical defect that workpiece surface defect information cannot be obtained due to blind machining is also avoided.

Description

Technical Field

[0001] This invention relates to the field of online detection of electrical discharge cutting, specifically to an online detection method and device for electrical discharge cutting. Background Technology

[0002] Electrical discharge machining (EDM) technology is widely used in various industrial fields due to its superior ability to precision machine high-hardness and high-strength materials. Its mechanism involves using a continuously moving filament electrode as the tool electrode in an insulating working fluid such as deionized water or kerosene. Through a controlled pulse discharge-generated instantaneous high-temperature plasma channel, the material on the workpiece surface is locally melted and vaporized, thus achieving micro-removal and continuous cutting. However, along with material removal, a large number of material particles and vaporization products continuously mix into the working fluid, causing a sharp decrease in the medium's transparency. The turbid liquid environment not only obscures the visual observation path but also strongly scatters or absorbs optical signals, making it impossible for operators to directly observe the workpiece or indirectly obtain information about surface defects using conventional optical or image sensing methods. This "blind machining" state poses a significant obstacle to real-time monitoring of discharge damage, analysis of damage mechanisms, and optimization of process parameters. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention discloses an online detection method and device for electrical discharge cutting.

[0004] The present invention adopts the following technical solution: The present invention discloses an online detection method for electrical discharge cutting, which is based on the detection of the workpiece by an experimental detection platform after the workpiece is cut by an electrical discharge cutting machine tool; The specific steps are as follows: S1. Load the clamping mechanism of the pre-installed workpiece onto the EDM machine tool for processing; S2. The workpiece is processed using a fixed-distance segmented processing method; S3. After completing the current processing segment, the clamping mechanism holding the processed workpiece is moved as a whole to the experimental testing platform. S4. The current processing section on the workpiece is detected and recorded using the supplementary lighting device and high-definition imaging device of the experimental testing platform. S5. After completing step S4, move the clamping mechanism holding the workpiece to the EDM machine tool again and start the next segment of fixed-distance machining from the current machining segment. S6. After completing step S5, inspect and record the workpiece being processed in the current fixed-distance processing section; S7. Repeat steps S3 to S6 above until the workpiece is machined according to the machining stroke.

[0005] The above-mentioned fixed-distance segmented processing method is calibrated according to the processing length of the workpiece, and the processing length is divided into multiple segments of the same length, with each segment representing the number of processing operations.

[0006] The present invention provides an online detection device for electrical discharge cutting, which is used in conjunction with an electrical discharge cutting machine tool including a worktable, a lower arm, a column, an upper arm, and an electrode wire. The worktable has a T-slot. The testing device includes a clamping mechanism for holding the workpiece and an experimental testing platform. The upper surface of the experimental testing platform is provided with a fixed chuck II for loading the clamping mechanism. A guide rail is provided on one side of the fixed chuck II. A slider is arranged on the guide rail. A fixed plate is arranged horizontally on the slider. A support rod for supporting the high-definition shooting device is arranged vertically on the fixed plate.

[0007] The online detection device for electrical discharge cutting described in this invention has a supplementary lighting device on the upper surface of the experimental detection platform, and the base of the experimental detection platform is a marble platform.

[0008] The online detection device for electrical discharge cutting described in this invention includes a clamping mechanism comprising upper and lower pressure plates for clamping the workpiece. Multiple aluminum profiles are used to support and fix the upper and lower pressure plates. The multiple aluminum profiles are combined and fixed to each other to form a stable aluminum profile support structure. The aluminum profile support structure is fixed by matching and fixing the zero-point positioning clamp with the fixed chuck.

[0009] The online detection device for electrical discharge cutting described in this invention has a fixed chuck on the worktable of the electrical discharge cutting machine tool that matches the zero-point positioning chuck. Beneficial effects

[0010] The online detection method for electrical discharge cutting provided by this invention can effectively detect the workpiece during the processing by using a fixed-distance multi-segment cutting processing method. The workpiece can freely switch between the processing equipment and the detection with the fixture, which improves the detection efficiency and avoids the technical defects of "blind processing" that cannot obtain the surface defect information of the workpiece.

[0011] The online detection and inspection device for electrical discharge cutting provided by this invention is characterized by using a zero-point positioning quick-change fixture as a mechanical interface to achieve sub-micron level repeatable positioning with "zero reference drift" switching between the machining station and the inspection station. This fixture utilizes a self-centering conical-ball-head locking structure to ensure that the positional error of the machining reference is always controlled within ±2 µm after the workpiece leaves the electrical discharge zone, is transferred, and resets. This maintains the original accuracy of electrical discharge cutting while avoiding the optical path obstruction problem caused by turbidity of the working fluid in traditional in-situ detection.

[0012] The high-definition imaging device is mounted on a slide rail-slider mechanism, allowing for arbitrary and stable adjustment of its position to record the damage status of the inspected workpiece from different angles. Furthermore, the supplementary lighting device mitigates the influence of environmental factors on the inspection results, effectively improving the device's adaptability. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the online detection device for electrical discharge cutting according to the present invention.

[0014] Figure 2 This is a schematic diagram of the electrical discharge cutting machine tool and its modification device used in this invention.

[0015] Figure 3 This is a schematic diagram of the experimental testing platform of the present invention.

[0016] Figure 4 This is a schematic diagram of the clamping mechanism of the present invention.

[0017] Figure 5 This is a partially enlarged structural schematic diagram of the electrical discharge cutting machine tool modification device of the present invention.

[0018] Figure 6 This is a structural block diagram of the online detection device for electrical discharge cutting according to the present invention.

[0019] Figure 7 This is a schematic diagram of the cutting path according to a preferred embodiment of the present invention.

[0020] In the diagram: 10-Electrical Discharge Cutting Machine Tool, 101-Worktable, 102-Lower Arm, 103-Column, 104-Upper Arm, 105-Electrode Wire, 20-Clamping Mechanism, 201-Clamping Upper Pressure Plate, 202-Clamping Support Plate, 203-Aluminum Profile Turning Angle Piece, 204-Aluminum Profile 1, 205-L-shaped Connecting Plate, 206-Right Angle Fixed Connector, 207-Aluminum Profile 2, 208-Aluminum Profile 3, 209-Zero Point Positioning Chuck, 30-Fixed Chuck I, 301-Swivel Chuck, 302-T-screw, 303-Flange Nut, 304-Pressure Plate, 40-Workpiece, 50-Experimental Testing Platform, 501-Marble Platform, 502-Guide Rail, 503-Limit Block, 504-Slider, 505-Fixed Plate, 506-Support Rod, 507-High-Definition Shooting Device, 508-Fill-in Light Device, 60-Fixed Chuck II (Disc Chuck). Detailed Implementation

[0021] To make the objectives and technical solutions of the embodiments of the present invention clearer, 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, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0022] like Figure 1 As shown: The clamping mechanism 20 of the present invention is used in the electrical discharge cutting machine tool 10 ( Figure 2 ) and online detection device 50 ( Figure 3 The process of transferring between ( )

[0023] like Figure 2 As shown: The electrical discharge cutting machine tool 10 used in this invention includes a worktable 101, a lower arm 102, a column 103, an upper arm 104, and an electrode wire 105. The worktable 101 has a T-slot, which is used to install and fix the chuck 30.

[0024] like Figure 3 As shown: The experimental testing platform 50 used in this invention includes a marble platform 501, a guide rail 502, a limiting block 503, a slider 504, a fixing plate 505, a support rod 506, a high-definition shooting device 507, and a supplementary lighting device 508.

[0025] In this embodiment, the base marble platform 501 of the experimental testing platform has a fixed chuck 60, which is a disc-shaped chuck, fixed on the marble platform 501 so that the clamping mechanism 20 can be locked on the experimental testing platform 50 to achieve the purpose of testing the workpiece 40.

[0026] A guide rail 502 is installed near the edge of the marble platform 501, with limiting blocks 503 at both ends of the guide rail 502. A slider 504 is placed on the guide rail 502 and positioned between the two limiting blocks 503. The limiting blocks 503 are used to prevent the slider from falling off the guide rail. A fixing plate 505 is fixed to the slider 504. The high-definition imaging device 507 is clamped onto the support rod 506. The support rod 506 is threadedly connected to the fixing plate 505 with screws. The fixing plate 505 is threadedly connected to the slider 504 with screws. The slider 504 can slide freely on the guide rail 502. The high-definition imaging device 507 is mounted on the slider-rail mechanism to facilitate position adjustment for recording workpieces at different positions and to prevent environmental factors from affecting the detection and recording results. The guide rail 502 is threadedly connected to the marble platform 501 with screws. The limiting block 503 is locked onto the guide rail 502 with set screws. Under certain circumstances, the position of the limiting block 503 can be adjusted using the set screws.

[0027] The disc-shaped chuck 60 and the marble platform 501 are connected by two screws.

[0028] like Figure 4 As shown: The present invention relates to a workpiece clamping mechanism, which includes a clamping upper pressure plate 201, a clamping support plate 202, and a zero-point positioning chuck 209.

[0029] In this embodiment, the aluminum profile support structure consists of an aluminum profile corner bracket 203, an aluminum profile one 204, an L-shaped connecting plate 205, a right-angle fixing connector 206, an aluminum profile two 207, and an aluminum profile three 208; the aluminum profile one 204, aluminum profile two 207, and aluminum profile three 208 form an "n" shaped structure; the aluminum profile three 208 and the aluminum profile two 207 are connected and fixed by the right-angle fixing connector 206 and the L-shaped connecting plate 205, and the aluminum profile two 207 and the aluminum profile one 205 are connected and fixed by the right-angle fixing connector 206 and the L-shaped connecting plate 205.

[0030] The aluminum profile 204 and the aluminum profile steering angle piece 203 are connected by screws. The clamp support plate 202 and the aluminum profile steering angle piece 203 are also connected by screws. The aluminum profile steering angle piece 203 enables the workpiece 40 to rotate in the horizontal and vertical planes, so as to adjust the posture of the workpiece 40 and improve the adaptability of the clamping mechanism 20.

[0031] A clamping upper pressure plate 201 is arranged above the clamping support plate 202. The workpiece is placed between the clamping upper pressure plate 201 and the clamping support plate 202. The clamping support plate 202 and the clamping upper pressure plate 201 are connected by screws. The internal thread of the clamping support plate 202 engages with the external thread of the screw. The fit between the clamping upper pressure plate 201 and the screw is a clearance fit. The clamping upper pressure plate 201 can slide freely along the screw shaft to clamp workpieces 40 of different thicknesses and improve the applicability of the clamping mechanism 20.

[0032] The right-angle fixing connector 206 is threadedly connected to the aluminum profile by screws. The function of the right-angle fixing connector 206 is to ensure that the two connected aluminum profiles are at right angles, providing a certain rigidity for the overall structure. The L-shaped connecting plate 205 is threadedly connected to the aluminum profile by screws. The function of the L-shaped connecting plate 205 is to increase the overall structural rigidity of the clamping mechanism 20.

[0033] A zero-point positioning chuck 209 is fixed at the bottom of aluminum profile 208, and the zero-point positioning chuck 209 is locked to aluminum profile 208 by two set screws; for example... Figure 4 It can be seen that the zero-point positioning chuck 209 has a fixed shaft extending downwards.

[0034] like Figure 5 As shown, the specific structure of the fixed chuck 30 on the EDM machine tool 10 includes: a swivel chuck 301, T-screws 302, flange nuts 303, and a pressure plate 304. The swivel chuck 301 is set on the worktable 101 of the EDM machine tool 10 so that the clamping mechanism 20 can be locked on the EDM machine tool 10 to achieve the purpose of processing the workpiece 40. The pressure plate 304 is placed in the groove of the swivel chuck 301, and each end of the pressure plate 304 is connected to a set of T-screws 302 and flange nuts 303. The T-shaped head of the T-screw 302 is placed in the T-slot of the worktable 101, and the flange nut 303 is placed at the tail of the screw. The function of the T-screws 302 and the flange nuts 303 is to connect the pressure plate 304 and the worktable 101, forcing the swivel chuck 301 to be stably installed on the worktable 101 of the EDM machine tool 10. The use of two sets of T-screws 302 and flange nuts 303 is to achieve the purpose of stably pressing the swivel chuck 301.

[0035] The clamping mechanism 20 can be locked to the fixed chuck 30 or the fixed chuck 60 by the zero-point positioning chuck 209, which facilitates installation and disassembly.

[0036] In conjunction with the above-described detection device, the online detection method for electrical discharge cutting of the present invention comprises the following specific steps: S1. Load the clamping mechanism of the pre-installed workpiece onto the EDM machine tool for processing; S2. The workpiece is processed using a fixed-distance segmented processing method; S3. After completing the current processing segment, the clamping mechanism holding the processed workpiece is moved as a whole to the experimental testing platform. S4. The current processing section on the workpiece is detected and recorded using the supplementary lighting device and high-definition imaging device of the experimental testing platform. S5. After completing step S4, move the clamping mechanism holding the workpiece to the EDM machine tool again and start the next segment of fixed-distance machining from the current machining segment. S6. After completing step S5, inspect and record the workpiece being processed in the current fixed-distance processing section; S7. Repeat steps S3 to S6 above until the workpiece is machined according to the machining stroke.

[0037] like Figure 6 , Figure 7 As shown, a specific example of the online detection method for electrical discharge cutting using the present invention is as follows: Assuming that the machining path used during the machining of workpiece 40 is a straight line, the total machining stroke is 50mm, and the given distance is 10mm.

[0038] Place the clamping mechanism 20 on the fixed chuck 30 of the EDM machine tool 10 (machining station) and lock it, then clamp the workpiece 40 on the clamping mechanism 20.

[0039] Start the electrical discharge cutting machine tool 10 to process the workpiece 40, process 10mm, and control the electrical discharge cutting machine tool 10 to make the workpiece 40 return to the starting point.

[0040] Keeping the relative position of the workpiece 40 and the clamping mechanism 20 unchanged, remove the clamping mechanism 20, transfer it to the fixed chuck 60 of the experimental testing platform 50 (testing station) and lock it.

[0041] Turn on the supplementary lighting device 508 and the high-definition imaging device 507 to inspect and record the workpiece 40.

[0042] After the inspection is completed, remove the clamping mechanism 20, transfer it to the fixed chuck 30 of the EDM machine tool 10 (machining station) and lock it.

[0043] Start the EDM machine tool 10, first move it 10mm without moving it to the previous processing position, then process it for another 10mm, and finally control the EDM machine tool 10 to make the workpiece 40 retract to the starting point.

[0044] The clamping mechanism is transferred to the experimental testing platform 50 (testing station) to complete the testing and recording of the workpiece 40, and then the clamping mechanism is transferred to the electrical discharge cutting machine tool 10.

[0045] Start the EDM machine tool 10, first move it 20mm without moving it to the previous processing position, then process it for another 10mm, and finally control the EDM machine tool 10 to make the workpiece 40 return to the starting point.

[0046] Repeat the above steps until the total machining stroke reaches 50mm, at which point the machining process is complete.

[0047] When using the clamping mechanism 20 to clamp the workpiece 40, sufficient clamping force should be ensured to prevent the workpiece 40 from falling off. In addition, when switching the clamping mechanism 20 between the EDM machine tool 10 (machining station) and the experimental testing platform 50 (testing station), the clamping mechanism 20 should be prevented from contacting other obstacles to prevent the position of the workpiece 40 from deflecting.

[0048] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An online detection method for electrical discharge cutting, characterized in that: This detection method is based on the process of cutting the workpiece using an electrical discharge cutting machine, followed by testing by an experimental testing platform. The specific steps are as follows: S1. Load the clamping mechanism of the pre-installed workpiece onto the EDM machine tool for processing; S2. The workpiece is processed using a fixed-distance segmented processing method; S3. After completing the current processing segment, the clamping mechanism holding the processed workpiece is moved as a whole to the experimental testing platform. S4. The current processing section on the workpiece is detected and recorded using the supplementary lighting device and high-definition imaging device of the experimental testing platform. S5. After completing step S4, move the clamping mechanism holding the workpiece to the EDM machine tool again and start the next segment of fixed-distance machining from the current machining segment. S6. After completing step S5, inspect and record the workpiece being processed in the current fixed-distance processing section; S7. Repeat steps S3 to S6 above until the workpiece is machined according to the machining stroke.

2. The online detection method for electrical discharge cutting according to claim 1, characterized in that, The fixed-distance segmented processing method is calibrated according to the processing length of the workpiece. The processing length is divided into multiple segments of equal length, and each segment represents the number of processing operations.

3. An online detection device for electrical discharge cutting, characterized in that: The device includes a clamping mechanism for holding workpieces and an experimental testing platform. The upper surface of the experimental testing platform is provided with a fixed chuck II for loading the clamping mechanism. A guide rail is provided on one side of the fixed chuck II. A slider is arranged on the guide rail. A fixed plate is arranged horizontally on the slider. A support rod for supporting the high-definition shooting device is arranged vertically on the fixed plate.

4. The online detection device for electrical discharge cutting according to claim 3, characterized in that: The upper surface of the experimental testing platform is also equipped with a supplementary lighting device, and the base of the experimental testing platform is a marble platform.

5. The online detection device for electrical discharge cutting according to claim 3, characterized in that: The clamping mechanism includes a clamping upper pressure plate and a clamping support plate for clamping the workpiece; Multiple aluminum profiles are used to support and fix the upper and lower pressure plates. The multiple aluminum profiles are combined and fixed to each other to form a stable aluminum profile support structure. The aluminum profile support structure is fixed by matching and fixing the zero-point positioning clamp with the fixed chuck.

6. The online detection device for electrical discharge cutting according to claim 3 or 5, characterized in that: The worktable of the EDM machine tool is equipped with a fixed chuck that matches the zero-point positioning chuck.

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