Unattended numerical control perforating method

Abstract

The present application relates to the technical field of perforation, and discloses an unattended numerical control perforation method, which comprises the following steps: controlling the downward movement of a first copper pipe by using a numerical control system, so that the first copper pipe passes through a guide and performs discharge perforation processing on a workpiece; monitoring the running state of the first copper pipe by using a state monitoring device during the downward movement of the first copper pipe or the discharge perforation processing, wherein the running state comprises a normal state and an abnormal state; transmitting the abnormal state monitored by the state monitoring device to the numerical control system in the form of an abnormal signal; after the first copper pipe contacts the workpiece, continuing the downward movement of the first copper pipe by a first set distance, or receiving the information that the first copper pipe has penetrated the lower surface of the workpiece to be processed by using a penetration detection system, and then controlling the first copper pipe to exit the workpiece to be processed and continue the processing of the next hole by using the numerical control system. The present application can monitor the running state of the first copper pipe in real time and automatically process the abnormality.

Description

Technical Field

[0001] This invention relates to the field of drilling methods, and more specifically to an unattended CNC drilling method. Background Technology

[0002] The electrical discharge machining (EDM) machine, also known as a drilling machine, punching machine, small hole machine, or fine hole discharge machine, works by using a thin metal copper tube that moves vertically up and down continuously as an electrode to perform pulsed spark discharge on the workpiece to remove metal and form it.

[0003] Currently, the electrical discharge machining (EDM) machines on the market include CNC drilling machines and CNC drilling machines with a higher degree of automation, such as automatic copper tube changing machines. However, due to the following reasons, manual operation is still required, and fully automated unmanned processing cannot be achieved.

[0004] First, the hollow copper tubes used in EDM drilling are thin, hollow metal copper tubes with an outer diameter of 0.1 mm to 3.0 mm. In general processing, hollow copper tubes with an outer diameter of less than 1.0 mm are generally used. The holes in the metal copper tubes are also divided into single holes and multiple holes. During processing, the processing fluid needs to pass through the hollow copper tube to cool the copper tube and the workpiece, and to flush away the residue eroded in the workpiece hole by the discharge.

[0005] Secondly, because the holes in hollow copper tubes are very small, they are easily blocked by impurities in the processing fluid or by the quality problems in the production of the hollow micro copper tubes themselves, causing the holes to become blocked and burn out, making it impossible to continue processing. Furthermore, if the machine is not stopped in time, the two ends of the broken copper tube will continue to contact and discharge, resulting in the workpiece being scrapped.

[0006] In addition, because the copper tube is very thin, it is very easy for the copper tube to bend when the discharge is unstable (e.g., when the voltage, current, processing parameters, water pressure, etc. change or are set unreasonably or inappropriately), or when there are stains or rust-preventive oils on the surface of the material to be processed, or when the material to be processed itself is impure, which will affect the processing quality or scrap the workpiece.

[0007] Furthermore, during automatic copper tube changing, if the copper tube fails to enter the guide smoothly, or if there are processing residues or damage within the guide, the CNC system cannot receive feedback to continue controlling the machine's operation. The copper tube will be bent, and if no one stops the machine, the copper tube changing command will be repeatedly executed until all the copper tubes in the hopper are scrapped. To prevent the copper tube from bending, many actions during processing must be performed at conservative operating speeds (e.g., processing with slower discharge parameters, very slow speed when the copper tube enters and passes through the guide, and extremely slow movement of the copper tube to the discharge position).

[0008] For the reasons mentioned above, existing perforation machines still require manual operation and cannot achieve fully automated, unmanned processing, nor can they realize the maximum processing efficiency that the machine tool should have. Summary of the Invention

[0009] The purpose of this invention is to provide a fully automated processing method that can handle copper tube abnormalities automatically, achieving maximum unattended CNC drilling processing, and has the function of real-time feedback of copper tube abnormalities to the CNC system, which greatly improves processing efficiency.

[0010] To achieve the above objectives, the technical solution adopted by this invention is: an unattended CNC drilling method, comprising: The first copper tube is controlled to move downward using a CNC system, so that after the first copper tube passes through the guide, the workpiece is subjected to electrical discharge drilling. During the downward movement of the first copper tube or the execution of electrical discharge drilling, a status monitoring device is used to monitor the operating status of the first copper tube, which includes a normal state and an abnormal state; and the abnormal state detected by the status monitoring device is transmitted to the CNC system in the form of an abnormal signal; the abnormal state includes at least one of the following: the first copper tube bending or the first copper tube melting. After the first copper tube contacts the workpiece, it continues to move downwards a first set distance, or after the penetration detection system receives information that the first copper tube has penetrated the lower surface of the workpiece, the CNC system controls the first copper tube to exit the workpiece and continue processing the next hole.

[0011] The method in the above scheme further includes: When the copper tube is automatically replaced, the CNC system is configured to: first lock the chuck of the rotating head to clamp the first copper tube, then control the rotating head to drive the first copper tube to rotate and move downward quickly through the guide to a second set distance, or control the rotating head to drive the first copper tube to rotate and move downward quickly through the guide to contact the workpiece to be processed, and then retract until the first copper tube and the workpiece to be processed are separated, and then perform electrical discharge machining.

[0012] In the above scheme, the method further includes, after transmitting the operating status to the CNC system, the following steps are also included: When the CNC system receives an abnormal operating status, the CNC system controls the rotary head to move upward until the abnormal status is resolved, or after the abnormal status is resolved, it moves upward a third set distance or a third set time before resuming processing; and / or, if the number of times the CNC system receives an abnormal status within a first set time is greater than a first set number, the CNC system issues a signal to stop operation and issue an alarm, or replaces the copper tube and continues automatic processing.

[0013] In the above scheme, the method further includes: when it is necessary to replace the copper tube, the CNC system outputs a signal to execute automatic copper tube replacement. The process of executing automatic copper tube replacement includes: during the process of the rotating head moving towards the preset initial position or at the preset initial position, the automatic feeding device feeds the first copper tube in the storage section into the rotating head spindle of the rotating head, and the first copper tube moves downward and passes through the sealing ring and the upper locking mechanism in sequence. The sealing ring is located in the rotating head spindle. When the lower end of the first copper tube moves to approach or contact the positioning detection part at the lower end of the copper tube, an electrical signal is generated by the positioning detection part at the lower end of the copper tube. Based on the electrical signal, the lower locking mechanism is controlled to lock the lower end of the first copper tube; and the rotating head is controlled to rise to the preset second position, or the lower locking mechanism is controlled to pull the copper tube down so that at least a part of the first copper tube is above the sealing ring, and the upper locking mechanism is used to lock the upper end of the first copper tube. Alternatively, based on the electrical signal, the upper locking mechanism can be controlled to lock the upper end of the first copper tube; After the upper end of the first copper tube is locked, the first copper tube is controlled to rotate and move downward, and the workpiece is processed by electrical discharge drilling using the first copper tube.

[0014] In the above scheme, the method further includes the following steps: during the automatic copper tube replacement process, if the CNC system receives an abnormal signal indicating an abnormal state, the CNC system outputs a signal to stop the automatic copper tube replacement, controls the copper tube to move until the abnormal state is resolved, and then outputs a signal to continue the automatic copper tube replacement; if the number of times the CNC system receives abnormal states for the same copper tube during the automatic copper tube replacement process is greater than or equal to a second set number, the CNC system issues a signal to stop operation and issue an alarm.

[0015] In the above scheme, the method further includes, after feeding the first copper tube in the storage section into the spindle of the rotating head, the method further includes: The second copper tube is restricted by the anti-second copper tube follower to prevent the second copper tube from entering the spindle of the rotating head. The second copper tube is any copper tube other than the first copper tube in the storage section. And / or, When the first copper tube needs to be replaced again, the restriction of the second copper tube follower part on the second copper tube is first released; or, the second copper tube follower part is used as a copper tube waiting part, and when the first copper tube needs to be replaced again, the restriction of the second copper tube entering the copper tube waiting part is first released. And / or, the anti-second copper tube follower part adopts at least one of the following methods: air blowing, blocking, clamping and squeezing, to prevent the second copper tube from following the first copper tube into the spindle of the rotating head.

[0016] In the above scheme, the method further includes, during the process of controlling the first copper tube to rotate downwards, using an automatic copper tube clamping device to hold the first copper tube; the automatic copper tube clamping device is configured as follows: Before the first copper tube rotates downward, the clamping assembly is at its lowest point due to its own weight, at which point the distance between the clamping assembly and the slider is at its maximum. The automatic copper tube support device includes at least a slider and a slide rail. The lower end of the slide rail is connected to the clamping assembly. During the process of controlling the first copper tube to rotate downward, when the chuck of the rotating head approaches the guide by a set distance, the clamping assembly opens the opening and closing part; During the process of controlling the first copper tube to rotate downward, the clamping component remains stationary relative to the copper tube until it reaches the preset blocking position and is blocked. At this time, the first copper tube continues to be processed downward, and the slide rail rises relative to the rotating head because its lower end is blocked. And / or, the clamping assembly is installed at the head of the machine between the guide and the rotating head, and when the rotating head descends to the fourth set distance, the clamping assembly opens the opening and closes and retracts from the copper tube.

[0017] In the above scheme, the clamping assembly adopts a pneumatic or electric mechanism; an elastic unit is provided at the opening and closing part of the clamping assembly. When the clamping assembly is closed, the elastic unit presses the copper tube laterally, and the elastic force of the elastic unit is less than the force that causes the first copper tube to deform.

[0018] In the above scheme, the method further includes stopping the alarm when the first copper tube continues to be conveyed downward for a second set time, a third set number of times, or a set distance without triggering the electrical signal of the lower end positioning detection unit of the copper tube.

[0019] In the above scheme, the method further includes that when the lower limit switch of the rotating head malfunctions, the rotating head overtravels, thereby triggering the status monitoring device to detect the abnormal state. Based on the abnormal signal of the received abnormal state, the CNC system executes at least one of the following two methods: stop the machine and alarm; or display a lower limit failure alarm on the display but continue processing, the status monitoring device replaces the lower limit function, and the alarm is reset after the lower limit switch is repaired.

[0020] In the above scheme, the status monitoring device is a hole-shaped conductor and is insulated from the rotating head. The copper tube passes through the hole, or the center of the hole is concentric with the guide. Alternatively, the status monitoring device may include one or at least two monitoring devices, wherein, in the at least two monitoring devices, at least one is configured to issue a first abnormal signal when the deformation of the copper tube is less than a preset threshold, and at least one is configured to issue a second abnormal signal when the deformation of the copper tube is greater than the preset threshold.

[0021] In the above scheme, the method further includes that during the processing, the CNC system compares the remaining length of the first copper tube with the preset data. When the remaining length of the first copper tube is insufficient to completely process the second hole, the CNC system outputs a signal to execute automatic copper tube replacement.

[0022] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art: This invention utilizes a status monitoring device to monitor the operating status of the first copper tube in real time. When an abnormality occurs in the first copper tube (such as bending or melting), the abnormal signal can be transmitted to the CNC system immediately. The CNC system can then further process the abnormal signal, thus enabling real-time monitoring of the first copper tube's operating status and automatic handling of abnormalities. Under normal conditions, the first copper tube moves downwards for processing. After contacting the workpiece, the first copper tube can continue moving downwards a predetermined distance, or after receiving information from the penetration detection system that the first copper tube has penetrated the lower surface of the workpiece, the timing of the first copper tube's exit from the workpiece can be determined. At this point, the CNC system controls the first copper tube to exit the workpiece and continue processing the next hole. The first copper tube automatically exits precisely when processing is complete. Using this method for perforation allows for fully automatic operation regardless of whether the copper tube is in a normal or abnormal state, achieving maximum unattended operation. This project greatly improves the success rate and processing efficiency of copper tube replacement, while expanding the adaptability of automatic copper tube replacement; it enables the drilling machine to achieve full automation, realize continuous automatic drilling, facilitate mass production, and save labor and time costs. Attached Figure Description

[0023] Figure 1 This is a flowchart illustrating an unattended CNC drilling method according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the structure of a CNC drilling method for achieving unattended operation in one embodiment of the present invention; Figure 3 This is a schematic diagram of a waste copper tube removal mechanism according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the automatic copper tube straightening device according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the status monitoring device structure in one embodiment of the present invention; Figure 6 This is a schematic diagram of the lower positioning detection unit in one embodiment of the present invention.

[0024] Among them, 100-machine head; 10-rotating head; 11-rotating head spindle; 20-material storage section; 30-upper locking mechanism; 40-lower locking mechanism; 50-guide; 60-lower positioning detection section; 80-automatic copper tube support device; 90-clamping assembly; 101-penetration detection system; 102-waste copper tube removal mechanism; 103-status monitoring device; 104-anti-second copper tube follow-up section; 105-first copper tube; 601-positioning mechanism; 602-detection mechanism. Detailed Implementation

[0025] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0026] like Figure 1 As shown, this application provides an unattended CNC drilling method, including: S1. The first copper tube is controlled to move downward using a CNC system, so that after the first copper tube passes through the guide, the workpiece is subjected to electrical discharge drilling. S2. During the downward movement of the first copper tube or the execution of electrical discharge drilling, the operating status of the first copper tube is monitored by the status monitoring device 103, which includes normal status and abnormal status; and the abnormal status monitored by the status monitoring device 103 is transmitted to the CNC system in the form of an abnormal signal; the abnormal status includes at least one of the following: the first copper tube bending or the first copper tube melting. S3. After the first copper tube contacts the workpiece, the first copper tube continues to move downwards a first set distance, or after the penetration detection system receives information that the first copper tube has penetrated the lower surface of the workpiece, the CNC system controls the first copper tube to exit the workpiece and continue processing the next hole.

[0027] like Figure 6As shown, this invention utilizes a status monitoring device 103 to monitor the operating status of the first copper tube in real time. When an abnormality occurs in the first copper tube (bending or melting), the abnormal signal can be transmitted to the CNC system immediately. The CNC system can then further process the abnormal signal, thus enabling real-time monitoring of the first copper tube's operating status and automatic handling of abnormalities. Under normal conditions, the first copper tube moves downwards for processing, and the timing of its exit from the workpiece can be determined using either of the two methods described above. The first copper tube automatically exits precisely at the completion of processing. Using this invention for piercing allows for fully automatic operation regardless of whether the copper tube is in a normal or abnormal state, achieving maximum unattended operation.

[0028] Generally, the method of allowing the first copper tube to continue moving downwards a first set distance after contacting the workpiece and then exiting the workpiece is typically used when machining blind holes (and for penetration machining where copper tube wear is relatively low or the copper tube wear ratio is stable). The method of using a penetration detection system to receive information that the first copper tube has penetrated the lower surface of the workpiece and then exiting the workpiece is used when a penetration hole is required. Both methods are available in CNC systems, and customers can choose which one to use.

[0029] like Figure 3 As shown, for example, during the processing, the penetration detection system 101 can be used to immediately retract the first copper tube 105 after the workpiece is penetrated. After processing one hole, the process can quickly move on to processing the next hole, further realizing automated drilling, improving the degree of automation, greatly improving drilling efficiency, and reducing copper tube consumption and labor costs. When the copper tube consumption is insufficient to complete the processing of the next hole, the waste copper tube removal mechanism 102 can be used to remove the remaining copper tube, and the process proceeds to the copper tube replacement step.

[0030] The method further includes: When the copper tube is automatically replaced, the CNC system is configured to: first lock the chuck of the rotating head to clamp the first copper tube, then control the rotating head to drive the first copper tube to rotate and move downward quickly through the guide to a second set distance, or control the rotating head to drive the first copper tube to rotate and move downward quickly through the guide to contact the workpiece to be processed, and then retract until the first copper tube and the workpiece to be processed are separated, and then perform electrical discharge machining.

[0031] The rotating head drives the copper tube to rotate, ensuring its smooth entry and passage through the guide (where processing residue can obstruct the tube's downward movement). Rapid movement to the discharge position improves processing efficiency (when EDM starts, the copper tube is already in the EDM state, making downward movement very slow; furthermore, if the outer wall of the copper tube contacts the inner wall of the hole to be processed, a discharge occurs, causing it to retract, making the process of reaching the discharge position much slower than reprocessing the hole). Because the status monitoring device 103 detects copper tube abnormalities and automatically handles bending issues, the tube's movement speed can be safely increased without worrying about the risk of bending due to incorrect second-set distance settings. Furthermore, the setting doesn't need to be extremely precise; a visual estimate is sufficient, making it safer and more efficient.

[0032] The first copper tube is controlled to move downwards to a second predetermined distance. The starting point is the position of the first copper tube when it is automatically replaced with a new one. The second predetermined distance is the position where the first copper tube is about to contact the workpiece, which can be used as the starting point for electrical discharge machining (EDM). Alternatively, to precisely control the copper tube to quickly reach the starting position for EDM, or when machining workpieces with irregular surfaces, the rotating head can be controlled to rotate the first copper tube and move it rapidly downwards through the guide until it contacts the workpiece, then retreats to the position where it separates from the workpiece. This serves as the starting point for EDM, ensuring that the copper tube reaches the desired EDM position as quickly as possible each time, without bending, greatly improving automation and production efficiency. Compared to existing technologies, Solution 1 (controlling the rotating head to rotate the first copper tube and move it rapidly downwards through the guide to the second predetermined distance and then retreats) allows for faster passage through the guide. Solution 2 (controlling the rotating head to rotate the first copper tube and move it rapidly downwards through the guide until it contacts the workpiece and then retreats) builds upon Solution 1, finding the EDM position even faster and more efficiently, especially when machining deep holes. (Because often the current hole has been processed to an unknown depth by the previous copper tube, the newly replaced copper tube can automatically and quickly pass through the already processed depth and accurately and quickly reach the position where the electrical discharge machining begins.) After transmitting the operating status to the CNC system, the process includes: When the CNC system receives an abnormal operating status, the CNC system controls the rotary head to move upward until the abnormal status is resolved, or after the abnormal status is resolved, it moves upward a third set distance or a third set time before resuming processing; and / or, if the number of times the CNC system receives an abnormal status within a first set time is greater than a first set number, the CNC system issues a signal to stop operation and issue an alarm, or replaces the copper tube and continues automatic processing.

[0033] During the downward movement of the first copper tube, deformation may occur. At this time, the status monitoring device 103 detects the abnormal state of the first copper tube and transmits the abnormal signal to the CNC system. The CNC system can control the rotating head to move upward so that the bent first copper tube returns to its normal state before continuing downward. If an abnormal state is encountered again, the above steps can be repeated. If the number of repetitions exceeds a first set number, such as three times, there may be obstacles that the CNC system cannot eliminate. In this case, operation needs to be stopped and an alarm triggered to notify management personnel to further eliminate the obstacles.

[0034] The unattended CNC drilling method in this embodiment may further include: like Figure 4 As shown, when the copper tube needs to be replaced, the rotating head 10, while running towards the preset initial position or at the preset initial position, uses an automatic feeding device to feed the first copper tube 105 in the storage section 20 into the rotating head spindle 11 of the rotating head 10, and causes the first copper tube 105 to move downward and pass through the sealing ring and the upper locking mechanism 30 in sequence. The sealing ring is located in the rotating head spindle 11. When the lower end of the first copper tube 105 moves to approach or contact the positioning detection part of the lower end of the copper tube, an electrical signal is generated by the positioning detection part of the lower end of the copper tube. After the electrical signal is generated, the first copper tube 105 can be locked and positioned using either of the following two methods: Option 1: Based on the electrical signal, control the lower locking mechanism 40 to lock the lower end of the first copper tube 105; and control the rotating head 10 to rise to the preset second position according to the length of the new copper tube, or control the lower locking mechanism to pull the copper tube down so that at least a part of the first copper tube 105 is above the sealing ring, and use the upper locking mechanism 30 to lock the upper end of the first copper tube 105. In Option 1, the preset initial position is the position below near the lower part of the machine head 100 and the guide 50, and the preset second position is the upper position, that is, near the upper part of the machine head 100; during the movement of the rotating head 10 towards the preset initial position, that is, during the downward movement, it can feed material from the storage section 20; or it can feed material from the storage section 20 when it reaches the preset initial position. Option 2: Based on the electrical signal, control the upper locking mechanism 30 to lock the upper end of the first copper tube 105; during the operation of the rotating head 10 towards the preset initial position, that is, during the upward or downward movement, it can feed material from the storage section 20, or it can feed material from the storage section 20 when it reaches the preset initial position; the preset initial position in Option 2 is above, that is, near the upper part of the machine head 100.

[0035] Based on the copper tube's conveying method or the size of the first copper tube 105, select either Option 1 or Option 2 to lock and position the first copper tube 105: Option 1 is more suitable for scenarios such as: thinner copper tubes are easily hindered by the surface tension of water or friction with other components due to their light weight, resulting in a slow descent speed. When the lower locking mechanism 40 is used for locking, the rotating head 10 is very close to the copper tube. It only needs to protrude slightly from the rotating head 10 to be detected. After being clamped by the lower locking mechanism 40, the rotating head 10 rises, easily overcoming the obstacle problem mentioned above when replacing copper tubes, making it faster.

[0036] Option 2 is more suitable for scenarios such as: thicker copper pipes are heavier, and when the copper pipe detaches from the upper end and falls freely, it is not easily hindered by the surface tension of the water or the resistance generated by other components, and the descent speed is fast. Option 2 can save a few seconds or more of the time that the rotating head 10 takes to come down and then go up, and also reduces the repeated friction of the lead screw and track, thus increasing their service life.

[0037] Based on different usage scenarios, one of the above solutions can be selected to lock the copper tube, and all of them can achieve the purpose of this invention.

[0038] After the upper end of the first copper tube 105 is locked, the first copper tube 105 is controlled to rotate and move downward, and the first copper tube 105 is used to perform electrical discharge drilling on the workpiece.

[0039] After the upper locking mechanism 30 locks the upper end of the first copper tube 105, it controls the first copper tube 105 to rotate downwards for processing. Because the copper tube detection part is fixedly installed and the distance between it and the sealing ring in the rotating head when the upper chuck is locked is preset according to the length of the copper tube, the upper end of the replaced copper tube will be just above the sealing ring. This means that the copper tube detection part determines the position of the lower end of the copper tube, which avoids wasting copper tube and prevents the upper end of the copper tube from being out of the sealing ring. It is also not affected by external processing conditions, ensuring that the top of the first copper tube is not lower than the sealing ring when changing the copper tube. During the copper tube replacement process, the first copper tube will not fall into the unfinished hole, causing the copper tube to leave the sealing ring. This can prevent the problem of automatic copper tube replacement failure if the surface of the workpiece is uneven and the distance between the guide and the rotating head is not adjusted according to the current surface height of each hole to be processed. This design is applicable to machining holes in workpieces of any height or with uneven surfaces, eliminating the need to constantly adjust the distance between the guide and the rotating head based on the workpiece surface. Simultaneously, the use of a hollow sealing ring reduces resistance to the downward movement of the copper tube, increasing its speed; and the use of a second copper tube follower eliminates machine downtime for maintenance and significantly improves the success rate of copper tube replacement.

[0040] During automatic copper tube changing, the rotating head drives the first copper tube downwards, allowing its lower end to enter and completely pass through the guide. However, this process can lead to abnormalities with the first copper tube. For example, the tube may deviate from its intended path and fail to enter the guide, or the guide may be damaged, preventing the tube from entering or passing smoothly, leaving processing residue in the guide. To address these issues, when an abnormality is encountered during automatic copper tube changing, a clamp or other device with a locking mechanism at the upper end of the first copper tube can be used to clamp or lock it. The rotating head then rises, lifting the tube. In other words, if an abnormal signal is generated during automatic copper tube changing, the downward feeding of the copper tube stops, and the tube is lifted until the abnormal signal is cleared before resuming the automatic copper tube changing process. If the same copper tube is triggered with an abnormal signal multiple times (more than or equal to a second set number, e.g., more than three times) during automatic copper tube changing, the machine stops and an alarm sounds, notifying personnel to handle the repeated abnormalities.

[0041] like Figure 6 As shown, in one embodiment, the copper tube detection unit includes a lower end positioning detection unit 60. The copper tube detection unit employs at least one of the following: electrical contact, conductive circuit detection, metal detection, light detection, and camera detection; for example, an open circuit electrical contact. As long as the lower end positioning detection unit 60 emits an electrical signal when the first copper tube 105 reaches its position, the objective of this invention can be achieved. The lower end positioning detection unit 60 may include a positioning mechanism 601 and a detection mechanism 602.

[0042] In one embodiment, the lower positioning detection unit 60 is located between the upper locking mechanism 30 and the workpiece. If the lower positioning detection unit is below the guide 50, the first copper tube 105 is locked after entering and completely passing through the guide 50, and then rotates downward to perform processing; this can also achieve the effect of preventing the copper tube from falling off during the copper tube replacement process, and is suitable for processing holes in workpieces with uneven surfaces.

[0043] like Figure 2 As shown, in one embodiment, after the first copper tube 105 in the storage section 20 is fed into the rotating head spindle 11 of the rotating head 10, the method further includes: S11. The second copper tube is restricted by the anti-second copper tube follower 104 to prevent it from entering the rotating head spindle 11 of the rotating head 10. The second copper tube is any copper tube other than the first copper tube 105 in the storage section 20. This is to prevent the second copper tube from slipping down with the first copper tube 105 during the copper tube replacement process due to vibration or the movement of the rotating head 10. Subsequently, after the copper tube is replaced, the water-stop cylinder needs to be activated to perform the water sealing process, which requires sealing the upper end of the rotating head spindle. This would cause a series of problems, such as the second copper tube following the first copper tube being bent and damaged, the water sealing mechanism being damaged, and water splashing out without a water seal damaging the rotating motor and other electrical components. This would also waste copper tubes and require a maintenance device to remove the second copper tube, affecting the processing progress. At the same time, the second copper tube follower section can be used as a copper tube waiting section. When the first copper tube is consumed and a new copper tube is replaced, the restriction on it can be lifted and it can immediately enter the rotating head spindle as a new first copper tube. This reduces the time for the copper tube to enter the conveying device from the storage section and be conveyed by the conveying device to the copper tube waiting section, further reducing the copper tube replacement time and increasing production efficiency.

[0044] S12. When it is necessary to replace the first copper tube 105 again, first release the restriction of the second copper tube on the second copper tube by the anti-second copper tube follower 104. Furthermore, the second copper tube follower 104 employs at least one of the following methods: air blowing, blocking, clamping, and squeezing, to prevent the second copper tube from following the first copper tube 105 into the rotating head spindle 11 of the rotating head 10. These methods can all be set to automatic control. Air blowing includes blowing air from bottom to top to prevent the second copper tube from slipping. The blocking device uses friction or elastic material to press against the first copper tube 105, or clamps all the leaking copper tubes other than the first copper tube 105 at the upper end of the storage section 20 (because the first copper tube 105 is no longer leaking at the upper end). Since the first copper tube 105 is pulled by the clamping component 90 and the second copper tube is in free fall, applying force to the first copper tube 105 will prevent the following second copper tube from slipping. Alternatively, an adjustable blocking device can close the opening for the second copper tube to slip, or other clamping or squeezing devices can prevent the second copper tube from slipping.

[0045] In one embodiment, during the downward rotation of the first copper tube 105, an automatic copper tube support device 80 clamps the first copper tube 105. The automatic copper tube support device 80 includes at least a slider and a slide rail. The slider remains relatively stationary or is connected to the rotating head 10. The lower end of the slide rail is connected to the clamping assembly 90. The clamping of the first copper tube 105 by the automatic copper tube support device 80 is configured as follows: like Figure 6As shown, before the first copper tube 105 is rotated and moved downward, the clamping assembly 90 is at its lowest point due to its own weight, at which point the distance between the clamping assembly 90 and the slider is at its maximum. During the downward rotation of the first copper tube 105, the clamping assembly 90 remains stationary relative to the copper tube until it reaches a preset blocking position. At this point, the first copper tube 105 continues to process downwards, while the slide rail rises relative to the rotating head 10 due to the lower end being blocked. When the chuck of the rotating head 10 approaches the guide 50 at a predetermined distance, the clamping assembly 90 opens its opening / closing position. The preset blocking position is located 1-10 cm above the guide 50, where a blocking element is provided to prevent the clamping assembly 90 from colliding with the guide 50 and other components as it continues to descend. Alternatively, the clamping assembly 90 may be installed at the machine head between the guide and the rotating head. When the rotating head descends to a fourth predetermined distance, the clamping assembly 90 opens its opening / closing position and retracts from the copper tube.

[0046] Preferably, the clamping assembly 90 is installed at the machine head 100 between the guide 50 and the rotating head 10. When the rotating head 10 descends to a set distance, the clamping assembly 90 opens its opening and closes and retracts from the copper tube, ensuring that the clamping assembly 90 avoids the downward-moving rotating head 10. Compared with the above scheme, the advantage is that it saves the length of copper tube occupied by the clamping assembly 90 that would otherwise be wasted on the perforation process.

[0047] The clamping assembly 90 employs a pneumatic or electric mechanism; an elastic unit is provided at the opening and closing point of the clamping assembly 90. The elastic unit can be made of materials that are easy to clamp without damaging the first copper tube 105, such as sponge, rubber, foam, silicone, or copper tube. The elastic force of the elastic unit is less than the force that deforms the first copper tube.

[0048] The copper tube can be supported by controlling the opening and closing of the clamping component 90. When the clamping component 90 is open, the space is used to facilitate the passage of the first copper tube 105. When the clamping component 90 is closed, the elasticity of the clamping component 90 after it is closed keeps the first copper tube 105 between the clamping components 90. This realizes automatic support of the copper tube during the processing, so that the first copper tube 105 remains relatively stable during the processing, reduces shaking, and improves the accuracy and speed of processing holes.

[0049] The method of this application also includes: stopping the machine and alarming when the first copper tube continues to be conveyed downward for a second set time, a third set number of times, or a set distance without triggering an electrical signal from the lower end positioning detection unit of the copper tube.

[0050] The second set time can be started when the rotating head reaches the position of the conveying copper tube. After the second set time, the third set number of times, or the set distance, if the electrical signal of the lower end positioning detection unit of the copper tube is not triggered, it means that the copper tube has moved many times or for a long time without receiving feedback from the lower end positioning detection unit. There is a problem with the copper tube delivery or there is no copper tube in the 20 storage section. At this time, the machine needs to be stopped and an alarm needs to be triggered.

[0051] When the lower limit switch of the rotary head malfunctions, the rotary head overtravels, causing the chuck on the rotary head (because the hole of the conductor is smaller than the chuck) to trigger the status monitoring device 103 to detect the abnormal state. Based on the abnormal signal of the received abnormal state, the CNC system executes at least one of the following two methods: stop the machine and alarm; or display a lower limit failure alarm on the display but continue processing, with the status monitoring device 103 replacing the lower limit function, and then resetting the alarm after the lower limit switch is repaired.

[0052] Each copper tube consumed triggers the lower limit switch, potentially hundreds of times a day. Therefore, as a consumable component, the lower limit switch is prone to failure, with serious consequences. The rotating head colliding with the guide plate can render the lead screw, track, motor, rotating head, guide plate, and the workpiece being processed unusable, necessitating monitoring. The status monitoring device 103 can be a conductor mounted on the guide plate. The lower limit switch limits the rotating head's travel to prevent overtravel and collision with the guide plate. The rotating head's movement is fed back to the CNC system in real-time position data. Assuming the real-time position data is 0 when the limit switch is triggered (positive for upward movement and negative for downward movement), a faulty limit switch will trigger the status monitoring device 103. If the CNC system receives negative real-time position data from the rotating head at this time, it can determine that the lower limit switch is faulty. The user can choose to ignore this and continue processing, essentially allowing the monitoring system to act as the button for the lower limit switch.

[0053] In one embodiment, the status monitoring device 103 is a hole-shaped conductor and is insulated from the rotating head. The copper tube passes through the hole, or the center of the hole is concentric with the guide. Alternatively, the status monitoring device 103 may include one or at least two monitoring devices, wherein at least one of the at least two monitoring devices is configured to issue a first abnormal signal when the deformation of the copper tube is less than a preset threshold, and at least one of the monitoring devices is configured to issue a second abnormal signal when the deformation of the copper tube is greater than the preset threshold.

[0054] In one embodiment, when only one layer is set, the magnitude of the copper tube deformation can be disregarded. The CNC system determines whether to control the rotary head to rise a certain distance for further processing or to stop and alarm based on the received signal. For example, if a signal indicating a small deformation is triggered three times within a set time, the first two times the head only rises without stopping, and the last time it stops and alarms. If a signal indicating a large deformation is given, the machine stops and alarms immediately. For example, if a layer with a large deformation is set on the upper layer, it can detect whether the automatic copper tube replacement was successful and whether the copper tube has been melted. This is because after melting, the upper copper tube, without the restraint of the guide, rotates and wobbles significantly due to the rotary head's movement from top to bottom. Furthermore, the lower copper tube that has been melted is inside the guide, and the subsequent copper tubes, unable to pass through the guide, bend and deform, which is detected. The magnitude of the deformation can be defined based on whether the copper tube can elastically recover to a straight state.

[0055] For example, if the upper copper tube has a large hole, the monitoring device for large deformation of the copper tube is located on the upper layer. If triggered, it indicates that the copper tube is severely deformed and cannot be restored to a straight shape, requiring scrapping. The machine must be stopped for manual processing or automatically replaced with a new copper tube. If the lower copper tube has a small hole, the monitoring device for small deformation of the copper tube is located on the lower layer. If triggered, the copper tube will only deform slightly, and after the rotating head rises, the copper tube can restore its straight shape and continue processing. Conversely, if the upper copper tube has a small hole, the monitoring device for large deformation of the copper tube is located on the lower layer. Based on the above principle, the status monitoring device 103 can also be configured with multiple layers as needed.

[0056] In one embodiment, during the machining process, the CNC system compares the remaining length of the first copper tube with pre-set data. When the remaining length of the first copper tube is insufficient to completely machine the second hole, the CNC system outputs a signal to automatically change the copper tube. After the first copper tube contacts the workpiece, it continues to move downwards a first set distance. Then, the CNC system controls the first copper tube to exit the workpiece and continue machining the next hole. This machining scheme requires this method to achieve unmanned operation.

[0057] This invention can reduce the time for changing copper tubes from more than one minute to within 30 seconds, doubling the efficiency and achieving a 100% success rate. It can reliably and automatically change copper tubes with a diameter of 0.3 mm or more, greatly improving the success rate and processing efficiency of copper tube changing, while also expanding the adaptability of automatic copper tube changing. It enables the drilling machine to achieve full automation, continuous automatic drilling, and facilitates mass production, saving labor and time costs.

[0058] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An unattended CNC drilling method, characterized in that, include: The first copper tube is controlled to move downward using a CNC system, so that after the first copper tube passes through the guide, the workpiece is subjected to electrical discharge drilling. During the downward movement of the first copper tube or the execution of electrical discharge drilling, the operating status of the first copper tube is monitored by a status monitoring device, which includes normal status and abnormal status. The abnormal status detected by the status monitoring device is transmitted to the CNC system as an abnormal signal; The abnormal state includes at least one of the following: the first copper tube is bent or the first copper tube is melted. After the first copper tube contacts the workpiece, it continues to move downwards a first set distance, or after the penetration detection system receives information that the first copper tube has penetrated the lower surface of the workpiece, the CNC system controls the first copper tube to exit the workpiece and continue processing the next hole.

2. The unattended CNC drilling method as described in claim 1, characterized in that, The method further includes: When the copper tube is automatically replaced, the CNC system is configured to: first lock the chuck of the rotating head to clamp the first copper tube, then control the rotating head to drive the first copper tube to rotate and move downward quickly through the guide to a second set distance, or control the rotating head to drive the first copper tube to rotate and move downward quickly through the guide to contact the workpiece to be processed, and then retract until the first copper tube and the workpiece to be processed are separated, and then perform electrical discharge machining.

3. The unattended CNC drilling method as described in claim 1, characterized in that, After transmitting the operating status to the CNC system, the process includes: When the CNC system receives an abnormal operating status, the CNC system controls the rotary head to move upward until the abnormal status is resolved, or after the abnormal status is resolved, it moves upward a third set distance or a third set time before resuming processing; and / or, if the number of times the CNC system receives an abnormal status within a first set time is greater than a first set number, the CNC system issues a signal to stop operation and issue an alarm, or replaces the copper tube and continues automatic processing.

4. The unattended CNC drilling method as described in claim 1, characterized in that, The method further includes: when it is necessary to replace the copper tube, the CNC system outputs a signal to execute automatic copper tube replacement. The process of executing automatic copper tube replacement includes: during the process of the rotating head moving towards the preset initial position or at the preset initial position, the automatic feeding device feeds the first copper tube in the storage section into the rotating head spindle of the rotating head, and the first copper tube moves downward and passes through the sealing ring and the upper locking mechanism in sequence. The sealing ring is located in the rotating head spindle. When the lower end of the first copper tube moves to approach or contact the positioning detection part at the lower end of the copper tube, an electrical signal is generated by the positioning detection part at the lower end of the copper tube. Based on the electrical signal, the lower locking mechanism is controlled to lock the lower end of the first copper tube; and the rotating head is controlled to rise to the preset second position, or the lower locking mechanism is controlled to pull the copper tube down so that at least a part of the first copper tube is above the sealing ring, and the upper locking mechanism is used to lock the upper end of the first copper tube. Alternatively, based on the electrical signal, the upper locking mechanism can be controlled to lock the upper end of the first copper tube; After the upper end of the first copper tube is locked, the first copper tube is controlled to rotate and move downward, and the workpiece is processed by electrical discharge drilling using the first copper tube.

5. The unattended CNC drilling method as described in claim 4, characterized in that, During the automatic copper tube replacement process, if the CNC system receives an abnormal signal indicating an abnormal state, the CNC system outputs a signal to stop the automatic copper tube replacement and automatically controls the copper tube to move until the abnormal state is resolved. Then, the CNC system outputs a signal to continue the automatic copper tube replacement. Alternatively, if the CNC system receives an abnormal state more than or equal to a second set number of times for the same copper tube during the automatic copper tube replacement process, the CNC system issues a signal to stop operation and issue an alarm or replaces the copper tube with a new one to continue automatic processing.

6. The unattended CNC drilling method as described in claim 4, characterized in that: After the first copper tube in the storage section is fed into the spindle of the rotating head, the process also includes: The second copper tube is restricted by the anti-second copper tube follower to prevent the second copper tube from entering the spindle of the rotating head. The second copper tube is any copper tube other than the first copper tube in the storage section. And / or, When the first copper tube needs to be replaced again, the restriction of the second copper tube follower part on the second copper tube is first released; or, the second copper tube follower part is used as a copper tube waiting part, and when the first copper tube needs to be replaced again, the restriction of the second copper tube entering the copper tube waiting part is first released. And / or, the anti-second copper tube follower part adopts at least one of the following methods: air blowing, blocking, clamping and squeezing, to prevent the second copper tube from following the first copper tube into the spindle of the rotating head.

7. The unattended CNC drilling method as described in claim 4, characterized in that, During the process of controlling the first copper tube to rotate downwards, an automatic copper tube support device clamps the first copper tube; the automatic copper tube support device clamping the first copper tube is configured as follows: Before the first copper tube rotates downward, the clamping assembly is at its lowest point due to its own weight, at which point the distance between the clamping assembly and the slider is at its maximum. The automatic copper tube support device includes at least a slider and a slide rail. The lower end of the slide rail is connected to the clamping assembly. During the process of controlling the first copper tube to rotate downward, when the chuck of the rotating head approaches the guide by a set distance, the clamping assembly opens the opening and closing part; During the process of controlling the first copper tube to rotate downward, the clamping component remains stationary relative to the copper tube until it reaches the preset blocking position and is blocked. At this time, the first copper tube continues to be processed downward, and the slide rail rises relative to the rotating head because its lower end is blocked. And / or, the clamping assembly is installed at the head of the machine between the guide and the rotating head, and when the rotating head descends to the fourth set distance, the clamping assembly opens the opening and closes and retracts from the copper tube.

8. The unattended CNC drilling method as described in claim 7, characterized in that, The clamping assembly is provided with an elastic unit at the opening and closing point. When the clamping assembly is closed, the elastic unit presses the copper tube laterally. The elastic force of the elastic unit is less than the force that causes the first copper tube to deform.

9. The unattended CNC drilling method as described in claim 4, characterized in that, If the first copper tube continues to be conveyed downwards for a second set time, a third set number of times, or a set distance without triggering an electrical signal from the positioning detection unit at the lower end of the copper tube, the machine will stop and alarm.

10. The unattended CNC drilling method as described in claim 1, characterized in that, When the lower limit switch of the rotary head malfunctions, the rotary head overtravels, triggering the status monitoring device to detect the abnormal state. Based on the abnormal signal of the received abnormal state, the CNC system executes at least one of the following two methods: stop the machine and alarm; or display a lower limit failure alarm on the display but continue processing, the status monitoring device replaces the lower limit function, and the alarm is reset after the lower limit switch is repaired.

11. The unattended CNC drilling method as described in claim 1, characterized in that, The status monitoring device is a hole-shaped conductor and is insulated from the rotating head. The copper tube passes through the hole, or the center of the hole is concentric with the guide. Alternatively, the status monitoring device may include one or at least two monitoring devices, wherein, in the at least two monitoring devices, at least one is configured to issue a first abnormal signal when the deformation of the copper tube is less than a preset threshold, and at least one is configured to issue a second abnormal signal when the deformation of the copper tube is greater than the preset threshold.

12. The unattended CNC drilling method as described in claim 1, characterized in that, During the processing, the CNC system compares the pre-set data with the remaining length of the first copper tube. When the remaining length of the first copper tube is insufficient to completely process the second hole, the CNC system outputs a signal to automatically change the copper tube.

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