A spark machine discharge health detection device and method

Abstract

This application discloses a discharge health detection device and method for an EDM machine, relating to the field of EDM equipment. It includes an EDM system controller for executing a discharge self-test program and outputting discharge control commands; a discharge drive module for receiving discharge control commands and generating drive signals; a voltage switching relay module for switching different discharge voltage paths in response to the drive signals, thereby driving the discharge power module to discharge through different discharge voltages; a discharge power module for controlling different discharge power units to independently perform discharge actions through drive signals; a current inductance module for real-time acquisition of discharge current signals from the discharge power units; and a current acquisition module for converting the discharge current signals into discharge waveform data. The EDM system controller is also used to determine the performance status of the discharge power units and the status of the discharge voltage paths and output a detection report. This application has the effect of automatically identifying faulty units and detecting the status of discharge paths.

Description

Technical Field

[0001] This application relates to the field of electrical discharge machining equipment, and in particular to a device and method for detecting the health of electrical discharge in an EDM machine. Background Technology

[0002] In the field of precision electrical discharge machining (EDM) equipment, EDM machines are typically equipped with multiple parallel discharge power units and multi-level discharge voltage paths to achieve complex machining. Existing technology has significant drawbacks: EDM machine systems lack the ability to independently test the performance of individual discharge power units. When abnormal discharge occurs, the specific faulty unit cannot be automatically located, requiring on-site troubleshooting by technicians, which is time-consuming and demands a high level of expertise. Furthermore, due to differences in electrical component parameters used by different manufacturers and fluctuations in manufacturing processes, the actual performance of discharge units in the same model of equipment can vary. However, existing systems cannot quantitatively evaluate the key performance indicators of each unit, nor can they detect the stability of the discharge voltage path. This results in incomplete performance testing before equipment leaves the factory, low efficiency in on-site fault repair, and seriously affects the continuity of industrial production and equipment reliability. There is an urgent need for a testing solution that can automatically identify specific faulty units, assess the voltage path status, and output a diagnostic report. Summary of the Invention

[0003] To address the shortcomings of traditional EDM (Electrical Discharge Machine) testing, such as incomplete detection and inability to pinpoint specific faulty units, this application provides an EDM discharge health detection device and method.

[0004] In the first aspect, the spark discharge health detection device provided in this application adopts the following technical solution: including a spark discharge system controller, a discharge drive module, a voltage switching relay module, a discharge power module, a current transformer module, and a current acquisition module; The EDM system controller is used to execute the discharge self-test program and output discharge control commands; The discharge drive module is connected to the EDM system controller and is used to receive the discharge control command and generate a drive signal. The voltage switching relay module is connected to the discharge drive module and is used to switch different discharge voltage paths in response to the drive signal so as to drive the discharge power module to discharge through different discharge voltages. The discharge power module includes multiple parallel discharge power units, which are respectively connected to the discharge drive module and the voltage switching relay module, and are used to control the discharge power units of different paths to independently perform discharge actions through the drive signal. The current transformer module is installed in the discharge circuit of each discharge power unit and is used to collect the discharge current signal of the discharge power unit in real time. The current acquisition module is connected to the current inductor module and is used to convert the discharge current signal into discharge waveform data. The EDM system controller is also used to receive the discharge waveform data transmitted by the current acquisition module, compare the discharge waveform data with preset standard waveform data to obtain a feature comparison result, determine the performance status of each discharge power unit and the status of the discharge voltage path based on the feature comparison result, and output a detection report.

[0005] By adopting the above technical solution, the EDM discharge health detection device integrates the EDM system controller, discharge drive module, voltage switching relay module, discharge power module, current transformer module, and current acquisition module, realizing automated health monitoring and diagnosis of the discharge process. This solution eliminates the need for external detection equipment, simplifies the health detection process, improves detection efficiency and accuracy, enables real-time status monitoring and preventative maintenance, reduces manual intervention costs and equipment downtime, thereby enhancing the reliability and ease of maintenance of the EDM system.

[0006] Optionally, the EDM system controller includes a discharge self-test execution unit and a waveform comparison and analysis unit; the discharge self-test execution unit is used to execute the discharge self-test program and output discharge control commands; the waveform comparison and analysis unit is used to receive the discharge waveform data transmitted by the current acquisition module, and perform feature comparison and analysis between the discharge waveform data and preset standard waveform data to obtain feature comparison results.

[0007] By adopting the above technical solution, the discharge self-test execution unit and waveform comparison analysis unit, which are separately set up in the EDM system controller, achieve functional decoupling. The discharge self-test execution unit is used to execute the discharge self-test program and accurately output control commands; the waveform comparison analysis unit performs deep feature extraction on the discharge waveform data transmitted by the current acquisition module, intelligently analyzes implicit features such as waveform distortion and oscillation attenuation, and performs multi-dimensional dynamic comparison with preset standard waveforms, significantly improving the analysis accuracy of feature comparison results. This solution not only enhances the early identification capability of abnormal discharge conditions, but also realizes the quantitative assessment of the performance degradation trend of the discharge power unit, and can accurately locate potential faults such as abnormal contact impedance in the discharge voltage path, making the detection report have fault prediction value. It significantly reduces the misjudgment rate of waveform comparison detection and comprehensively improves the intelligent diagnostic level and operational reliability of the EDM discharge health detection device.

[0008] Optionally, the voltage switching relay module includes a relay array unit, an isolation unit, and a transient suppression unit; the relay array unit is used to switch different discharge voltage paths in response to the drive signal; the isolation unit is used to prevent voltage interference during the switching of the discharge voltage path, ensuring that the discharge power module is driven to discharge through different discharge voltages; the transient suppression unit is used to actively absorb voltage spikes and arc energy when switching the discharge voltage path; wherein, the transient suppression unit includes a nonlinear resistive element and an energy absorption circuit, the nonlinear resistive element is used to suppress the voltage spikes, and the energy absorption circuit is used to dissipate the arc energy.

[0009] By adopting the above technical solution, the voltage switching relay module achieves precise control and safety protection of the discharge voltage path through structured design. The relay array unit responds to the drive signal to quickly switch the discharge voltage path, ensuring flexible adaptation to multiple voltage scenarios. The isolation unit effectively blocks voltage crosstalk and electromagnetic interference during switching, ensuring the drive purity of the discharge power module under different voltage levels; the transient suppression unit clamps voltage spikes in real time through nonlinear resistor elements, combined with the energy absorption circuit actively dissipating the arc energy generated during switching, suppressing overvoltage and electromagnetic transient impacts from the source. This solution significantly improves the stability and safety of the high-voltage switching process, avoiding damage to power devices or distortion of detection waveforms caused by voltage transients, while reducing electromagnetic compatibility risks. Through the synergistic effect of multiple protection mechanisms, the service life of the voltage switching relay module is extended, and the acquisition accuracy of the discharge current signal is ensured, providing a highly reliable hardware foundation for EDM discharge health detection, and further strengthening the system's anti-interference capability and long-term operational stability under complex operating conditions.

[0010] Optionally, the transient suppression unit further includes a mode prediction subunit and a collaborative optimization subunit; the mode prediction subunit is used to establish a dynamic behavior model of the voltage spike and the arc energy based on the feature comparison results, and obtain prediction results based on the dynamic behavior model; the prediction results include the occurrence probability and intensity pattern of the voltage spike and the arc energy; the collaborative optimization subunit is connected to the mode prediction subunit and is used to dynamically coordinate the conduction threshold of the nonlinear resistive element and the energy distribution strategy of the energy absorption circuit according to the prediction results; wherein, the collaborative optimization subunit is also connected to the discharge drive module to obtain the timing characteristics of the drive signal, and optimize the update frequency of the dynamic behavior model based on the timing characteristics, thereby realizing the adaptive collaborative control of the transient suppression unit.

[0011] By adopting the above technical solution, the transient suppression unit achieves a breakthrough improvement in protection effectiveness through intelligent prediction and dynamic optimization mechanisms. The pattern prediction subunit constructs a dynamic behavior model of voltage spikes and arc energy based on the feature comparison results transmitted by the EDM system controller, accurately predicting their probability of occurrence and intensity patterns. The collaborative optimization subunit adjusts the conduction threshold of the nonlinear resistive element in real time according to the prediction results and dynamically allocates the dissipation strategy of the energy absorption circuit. Simultaneously, it optimizes the model update frequency by combining the timing characteristics of the discharge drive module, forming a closed-loop adaptive control. This solution upgrades traditional passive suppression to active predictive protection, significantly improving the suppression accuracy and response speed for transient overvoltages and arcs. On the one hand, it reduces the ineffective operating losses of the nonlinear resistive element through predictive adjustment, extending its service life; on the other hand, it optimizes the dynamic allocation efficiency of the energy absorption circuit, avoiding secondary interference caused by energy accumulation. By employing a predictive-optimization collaborative mechanism, not only are electromagnetic transient risks during high-voltage switching effectively suppressed, but energy losses of the protective components themselves are also significantly reduced. This provides an ultra-low-noise electrical environment for the acquisition of discharge current signals, thereby enhancing the reliability of health monitoring data and ultimately achieving a synergistic leap in the full life-cycle protection effectiveness and operational stability under complex operating conditions.

[0012] Optionally, the discharge power module includes multiple parallel discharge power units; each discharge power unit includes a discharge resistor subunit and a MOS switch subunit; the discharge resistor subunit is used to provide a fixed resistance value; the MOS switch subunit is used to control the discharge action through the drive signal.

[0013] By adopting the above technical solution, the discharge power module achieves refined control and efficient execution of the discharge process through a multi-channel parallel discharge power unit design. Each discharge power unit integrates a discharge resistor subunit to provide a stable fixed resistance value, ensuring the consistency of the discharge current reference. Simultaneously, the MOS switch subunit responds to the drive signal to precisely control the start, stop, and intensity of the discharge action, enabling independent operation of multiple units. This solution not only improves the controllability and response speed of the discharge action but also reduces the interference of current fluctuations on the detected waveform data by using a fixed resistance value, ensuring the purity of the discharge current signal. The multi-channel parallel design supports flexible configuration of different discharge scenarios, avoiding the impact of single-point failures on overall operation and enhancing the redundancy and reliability of the discharge power module. This solution significantly optimizes the accuracy and stability of EDM discharge health detection, reduces the risk of misjudgment due to resistance drift or switching delay, simplifies hardware maintenance complexity, and reduces energy consumption and component losses, thereby comprehensively improving the long-term operating efficiency and maintenance economy of the EDM discharge health detection device.

[0014] Optionally, the current acquisition module includes a current signal conversion unit and a dynamic filtering unit; the current signal conversion unit is used to convert the discharge current signal acquired by the current inductor module into discharge waveform data; the dynamic filtering unit is used to adjust the filtering parameters in real time based on the noise characteristics of the discharge waveform data and perform adaptive filtering processing; the dynamic filtering unit uses a digital signal processor to dynamically update the filtering parameters to match the noise patterns of different discharge power units.

[0015] By adopting the above technical solution, the current acquisition module significantly improves the processing accuracy and anti-interference capability of discharge waveform data through an intelligent dynamic filtering mechanism. The current signal conversion unit efficiently converts the discharge current signal acquired by the current inductor module into analyzable discharge waveform data; the dynamic filtering unit monitors the noise characteristics of the waveform data in real time, dynamically adjusts the filtering parameters using a digital signal processor, and performs adaptive filtering to accurately match the noise patterns of different discharge power units. This solution effectively suppresses the influence of environmental electromagnetic interference and inherent circuit noise on the signal, ensuring the purity and authenticity of the waveform data. The adaptive mechanism avoids the overfitting or under-filtering problems of traditional fixed filtering, reducing the risk of waveform distortion and misjudgment caused by noise; at the same time, the real-time updating of filtering parameters optimizes processing efficiency and reduces the need for manual calibration and hardware resource consumption. This solution not only significantly improves the data reliability and diagnostic accuracy of EDM discharge health detection, but also provides high-fidelity input for performance status determination, thereby enhancing the stability and maintenance convenience of the device under complex operating conditions and achieving an overall leap in detection efficiency.

[0016] Optionally, an adaptive calibration module is also included; the adaptive calibration module is connected to the EDM system controller and is used to dynamically update the standard waveform database based on the discharge waveform data detected multiple times, so as to adapt to the parameter differences of the components of the discharge power unit in different paths.

[0017] By adopting the above technical solution, the adaptive calibration module achieves dynamic optimization of the standard waveform database and system self-evolution through a closed-loop learning mechanism. Based on multiple discharge waveform data transmitted from the EDM system controller, this adaptive calibration module continuously analyzes the component parameter drift, aging characteristics, and individual differences of different discharge power units, intelligently correcting the benchmark threshold and tolerance range of the standard waveform data to ensure that the comparison benchmark always matches the actual operating conditions. This solution effectively overcomes the misjudgment problem caused by batch differences or performance degradation of components in traditional fixed standard libraries, significantly improving the adaptability and accuracy of feature comparison results. The adaptive update mechanism avoids the tedious operation of manual periodic calibration, reducing maintenance costs and downtime. Simultaneously, by accumulating historical data to build a component performance degradation model, it provides early warning indicators for preventative maintenance. This solution not only enhances the diagnostic reliability of EDM discharge health detection throughout the entire equipment lifecycle but also achieves self-synchronous optimization of detection standards and hardware status, significantly improving the long-term stability and diagnostic confidence of the system, providing sustainable technical support for accurate status monitoring in complex industrial environments.

[0018] Optionally, the adaptive calibration module includes a coefficient of variation analysis unit, an aging attenuation compensation unit, and a lifetime prediction unit; the coefficient of variation analysis unit is used to dynamically adjust the update threshold of the standard waveform database based on the dispersion of the discharge waveform data; the aging attenuation compensation unit is used to calculate the attenuation coefficient of the component based on the usage time of the discharge power unit and the dispersion, and dynamically correct the update threshold of the standard waveform database; the lifetime prediction unit is used to calculate the remaining lifetime of the discharge power unit based on the attenuation coefficient and the dispersion, and output the remaining lifetime prediction result through the EDM system controller.

[0019] By adopting the above technical solution, the adaptive calibration module achieves accurate evolution and lifespan prediction of the standard waveform database through a hierarchical intelligent analysis mechanism. The coefficient of variation analysis unit dynamically adjusts the update threshold based on the distribution and dispersion of the discharge waveform data, ensuring a strict match between the correction of the standard waveform data and its volatility. The aging attenuation compensation unit combines historical data and dispersion characteristics of the discharge power unit's usage time to calculate the component attenuation coefficient and calibrate the update threshold in real time, effectively offsetting the impact of performance drift on the benchmark. The lifespan prediction unit integrates the attenuation coefficient and dispersion to construct a remaining lifespan model, outputting quantitative prediction results through the EDM system controller. This solution breaks through by upgrading the calibration function from passive adaptation to active prediction. The coefficient of variation analysis ensures the statistical rationality of the threshold update, the aging compensation mechanism accurately isolates the interference of natural component attenuation and sudden failures, and lifespan prediction reveals the performance degradation inflection point in advance. The synergy of these three components not only significantly improves the reliability of the standard waveform database throughout the equipment's entire lifespan but also enhances the ability to predict anomalies, significantly reducing the rate of sudden failures and unplanned downtime losses. Furthermore, by accurately quantifying component lifespan and optimizing spare parts management strategies, it ultimately achieves the globally optimal balance between maintenance costs and operational stability of the EDM discharge health detection device.

[0020] Optionally, the EDM system controller is also configured to automatically trigger an additional self-test program based on the remaining service life prediction result; when the remaining service life prediction result is lower than a preset service life threshold, the EDM system controller re-executes the discharge self-test program and updates the feature comparison result and the test report.

[0021] By adopting the above technical solution, the EDM system controller achieves dynamic enhancement of predictive maintenance through an intelligent linkage mechanism. It deeply integrates lifespan prediction with self-testing actions, forming a closed-loop response. On one hand, threshold-driven proactive retesting promptly captures critical degradation of component performance, avoiding sudden failures or detection distortions caused by lifespan depletion. On the other hand, updated feature comparison results and test reports enhance data real-time performance, providing highly reliable evidence for maintenance decisions. This solution significantly improves the EDM discharge health detection device's ability to predict and intervene in aging risks, reduces unplanned downtime and manual checks, optimizes the dynamic allocation of maintenance resources, extends the effective service life of key components, and ultimately achieves a synergistic improvement in the reliability, economy, and safety of the EDM discharge health detection device throughout the equipment's entire lifecycle.

[0022] Secondly, the present invention provides a method for detecting the health of an EDM discharge, applied to the EDM discharge health detection device provided in the first aspect, the method comprising the following steps: S1. The discharge self-test program is executed and the discharge control command is output through the EDM system controller; S2. Receive the discharge control command and generate a drive signal through the discharge drive module; S3. By using a voltage switching relay module, different discharge voltage paths are switched in response to the drive signal to drive the discharge power module to discharge. S4. The discharge power module uses the drive signal to control the discharge power unit to independently perform the discharge action; S5. The discharge current signal of the discharge power unit is acquired in real time through the current transformer module; S6. The discharge current signal is converted into discharge waveform data through the current acquisition module; S7. The discharge waveform data is received through the EDM system controller, and the discharge waveform data is compared with the preset standard waveform data to obtain the feature comparison result. Based on the feature comparison result, the performance status of the discharge power unit and the status of the discharge voltage path are determined, and a detection report is output.

[0023] The technical effects of the method of the present invention are similar to those of the first aspect, and will not be repeated here.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. By adopting the method of executing the discharge self-test program by the EDM system controller and performing feature comparison analysis based on discharge waveform data, combined with the real-time conversion function of the current acquisition module, the system can automatically complete the entire process from discharge action to performance status judgment. This effectively solves the problems of low efficiency and high misjudgment rate caused by traditional EDM detection relying on manual visual inspection or simple threshold judgment. As a result, it achieves high precision, real-time performance and reliability of discharge health detection, and improves the level of intelligent equipment maintenance. 2. Due to the adoption of the transient suppression unit in the voltage switching relay module, including the dynamic behavior model construction and adaptive control mechanism of the mode prediction subunit and the collaborative optimization subunit, the system can actively absorb voltage spikes and arc energy when switching discharge voltage paths. This effectively solves the risk of equipment failure caused by transient interference and insufficient energy dissipation during high voltage switching, thereby enhancing the stability and safety of the discharge process and extending the service life of key components. 3. By adopting the coefficient of variation analysis unit and aging attenuation compensation unit of the adaptive calibration module, combined with the remaining service life calculation function of the life prediction unit, the system can dynamically update the standard waveform database and trigger additional self-test programs. This effectively solves the problems of standard data failure and test result deviation caused by component aging or parameter drift, thereby realizing the self-optimization and predictive maintenance capabilities of the EDM health detection device and providing continuous and reliable decision support for equipment health management. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a module structure diagram of the spark discharge health detection device provided in the embodiments of this application; Figure 2 This is a unit structure diagram of the spark discharge health detection device provided in the embodiments of this application; Figure 3 This is a schematic diagram of the parameters of the spark discharge health detection device provided in the embodiments of this application; Figure 4 This is a schematic diagram of the fitting range of the spark discharge health detection device provided in the embodiments of this application; Figure 5 This is a circuit connection diagram of the spark discharge health detection device provided in the embodiments of this application; Figure 6 This is another structural diagram of the spark discharge health detection device provided in Embodiment 2 of this application; Figure 7 This is a flowchart of the spark discharge health detection method provided in the embodiments of this application.

[0027] Figure reference numerals: 1. EDM system controller; 11. Discharge self-test execution unit; 12. Waveform comparison and analysis unit; 2. Discharge drive module; 3. Voltage switching relay module; 31. Relay array unit; 32. Isolation unit; 33. Transient suppression unit; 331. Nonlinear resistor element; 332. Energy absorption circuit; 333. Mode prediction subunit; 334. Collaborative optimization subunit; 4. Discharge power module; 41. Discharge power unit; 411. Discharge resistor subunit; 412. MOS switch subunit; 5. Current transformer module; 51. Current transformer; 6. Current acquisition module; 61. Current signal conversion unit; 62. Dynamic filtering unit; 7. Adaptive calibration module; 71. Coefficient of variation analysis unit; 72. Aging attenuation compensation unit; 73. Lifetime prediction unit. Detailed Implementation

[0028] The following is in conjunction with the appendix Figure 1 - Appendix Figure 7 This application will be described in further detail.

[0029] This application discloses a device and method for detecting the health of EDM discharge.

[0030] See attached document Figure 1 A discharge health detection device for an EDM machine includes an EDM system controller 1, a discharge drive module 2, a voltage switching relay module 3, a discharge power module 4, a current transformer module 5, and a current acquisition module 6.

[0031] The EDM system controller 1 is electrically connected to the discharge drive module 2. The discharge drive module 2 is electrically connected to the voltage switching relay module 3 and the discharge power module 4 respectively. The voltage switching relay module 3 is electrically connected to the discharge power module 4. The discharge power module 4 is electrically connected to the current transformer module 5. The current transformer module 5 is electrically connected to the current acquisition module 6. The current acquisition module 6 is electrically connected to the EDM system controller 1.

[0032] See attached document Figure 2 Specifically, the EDM system controller 1 includes a discharge self-test execution unit 11 and a waveform comparison and analysis unit 12; the voltage switching relay module 3 includes a relay array unit 31, an isolation unit 32 and a transient suppression unit 33; the discharge power module 4 includes multiple parallel discharge power units 41; each discharge power unit 41 includes a discharge resistor subunit 411 and a MOS switch subunit 412; the current acquisition module 6 includes a current signal conversion unit 61 and a dynamic filtering unit 62; and the current transformer module 5 includes a current transformer 51.

[0033] The EDM system controller 1 first performs a power-on self-test via the discharge self-test execution unit 11. Then, the discharge self-test execution unit 11 transmits the discharge control command to the waveform comparison and analysis unit 12 for feature comparison via a communication connection. The discharge self-test execution unit 11 transmits the discharge control command to the discharge drive module 2 via the communication connection. The discharge drive module 2 generates a drive signal from the received discharge control command and transmits it to the discharge power unit 41 to control the on / off state of the MOS switch subunit 412. Simultaneously, the drive signal is transmitted to the relay array unit 31 to switch different discharge voltage paths. The relay array unit 31 is electrically connected to the isolation unit 32 to prevent voltage interference during the switching of different discharge voltage paths. The isolation unit 32 is electrically connected to the transient suppression unit 33 to actively absorb voltage spikes and arc energy when switching different discharge voltage paths. The transient suppression unit 33 includes a nonlinear resistor element 331 and an energy absorption circuit 332. The nonlinear resistor element 331 is used to suppress voltage spikes, and the energy absorption circuit 332 is used to dissipate arc energy. The voltage switching relay module 3 switches different discharge voltage inputs to the discharge power unit 41 via electrical connection. The discharge power unit 41 transmits the discharge current signal of each discharge power unit 41 to the current transformer 51 via electrical connection. The current transformer 51 transmits the discharge current signal to the current signal conversion unit 61, which converts it into discharge waveform data. The current signal conversion unit 61 transmits the discharge waveform data to the dynamic filtering unit 62 via communication connection. After dynamic filtering, it transmits the data to the EDM system controller 1 via communication connection. The controller 1 compares the discharge waveform data with preset standard waveform data to obtain the feature comparison result. Based on the feature comparison result, the controller determines the performance status of each discharge power unit 41 and the status of the discharge voltage path, and outputs a detection report.

[0034] The EDM system controller 1 is used to execute the discharge self-test program and output discharge control commands, including the discharge self-test execution unit 11 and the waveform comparison and analysis unit 12.

[0035] In this embodiment, the discharge self-test execution unit 11 is used to execute the discharge self-test program and output discharge control commands; the waveform comparison and analysis unit 12 is used to receive the discharge waveform data transmitted by the current acquisition module 6, and compare the discharge waveform data with the preset standard waveform data to obtain the feature comparison result; based on the feature comparison result, the performance status of each discharge power unit 41 and the status of the discharge voltage path are determined and a test report is output.

[0036] Before executing the discharge self-test procedure, the electrical cabinet must be powered on and reset, and the EDM system controller 1 must be in a ready state. The EDM system controller 1 interface will have a self-test start button. Clicking the self-test button will cause the discharge self-test execution unit 11 to control the self-test dedicated circuit to engage, without requiring any additional operation from the operator.

[0037] The preset standard waveform data uses a short-circuit test conducted using an oscilloscope on a calibrated standard EDM cabinet at an ideal voltage, i.e., the machine tool's main power supply is connected to a regulated power supply to ensure a three-phase AC380 condition. The waveforms obtained are close to the ideal waveforms.

[0038] See attached document Figure 3 Specifically, the current waveform of each normal discharge power unit 41 mainly has three reference parameters: A. pulse width, B. peak value, and C. rising edge slope.

[0039] A. The pulse width determines the effective value of the discharge current of the discharge power unit 41. It is generally related to the switching frequency of the MOSFET and is controlled by the EDM system controller 1. A fixed pulse width is used during health checks. B. The peak value is the peak value of the discharge current of the discharge power unit 41. The magnitude of the peak discharge current is related to the resistance and voltage of the discharge resistor subunit 411 of each discharge power unit 41. A fixed voltage is used during health checks, and the resistance of each discharge resistor subunit 411 must be fixed. For different EDM machines, the resistance values ​​of resistors purchased from different channels will vary.

[0040] The rise slope of C primarily reflects current loss. It is mainly affected by the inductance of the discharge resistor subunit 411 and the inductance of the discharge loop. A smaller inductance results in a smaller slope and higher discharge efficiency. Furthermore, due to differences in resistance and inductance values ​​between different types of discharge resistor subunits 411 (e.g., the difference between flat-wound and round-wound inductance values) and variations in wiring methods across different electrical cabinets, the inductance of the discharge loop varies considerably, leading to significant differences in the rise slope of C, which also affects discharge efficiency.

[0041] See attached document Figure 3 With appendix Figure 4The EDM system controller 1 calculates a fitting interval based on the standard current waveform of the discharge power unit 41. This fitting interval is a floating data space calculated by taking the standard waveform data and allowing it to fluctuate by 10%. The collected discharge current waveform is then filtered and placed into this fitting space for comparison using a similarity algorithm. If the similarity is greater than or equal to 90%, it is considered to fit the fitting interval. If it fits the fitting interval, the discharge performance of the discharge power unit 41 meets the standard; otherwise, it does not. Finally, the differences between the three parameters (A) pulse width, B peak value, and C rise edge slope and the standard parameters are analyzed.

[0042] Simultaneously, a test report is generated to remind users of discharge power units 41 whose discharge performance fails to meet the standards. If the difference in pulse width A is large, the test report should remind users to: check whether the MOS transistor in the MOS switch subunit 412 is normal, check whether the GATE board software version of the discharge drive module 2 is the production version, and replace the GATE board for retesting.

[0043] If the peak current of B varies significantly, the test report should remind you to: check whether the resistance value of the discharge resistor subunit 411 used for production meets the design requirements of the discharge circuit; check whether there is a problem with the total voltage of the machine tool power supply, which is generally AC380V±10%; if the peak current of B in all circuits is zero, check whether there is voltage in the discharge voltage path in the voltage switching relay module 3, and check whether the power supply line and components are abnormal; if only a few circuits have zero peak current of B, use a multimeter to measure and check whether the MOS transistors of these MOS switch subunits 412 are normal. If a problem is found, replace the spare MOS board or repair and replace it.

[0044] If the slope of the rising edge of C differs significantly, the test report should remind you to: check whether the resistance value of the discharge resistor subunit 411 used in production meets the circuit design requirements; check whether the resistance wire of the discharge resistor subunit 411 is twisted in pairs according to production requirements; check whether the resistance wire of the discharge resistor subunit 411 is too long; and check whether the wiring layout of the discharge voltage path is reasonable.

[0045] The discharge drive module 2 is used to receive discharge control commands and generate drive signals. The discharge drive module 2 can typically use a GATE board as its core component; the GATE board refers to the circuit board related to gate circuits, and in this embodiment, a power gate driver board used to drive high-power switching devices is selected.

[0046] The voltage switching relay module 3 is used to switch different discharge voltage paths in response to the drive signal so as to drive the discharge power module 4 to discharge through different discharge voltages. It includes a relay array unit 31, an isolation unit 32 and a transient suppression unit 33.

[0047] In this embodiment, the relay array unit 31 is used to switch different discharge voltage paths in response to drive signals. The relay array unit 31 selects electromagnetic relays or solid-state relay arrays as its core components. Its function is to respond to the drive signals from the discharge drive module 2 and quickly switch different discharge voltage paths, such as the four voltage sources commonly found in EDM machines, to achieve drive control of applying different voltages to the same discharge power unit 41. When the EDM system controller 1 issues a discharge control command for a specific voltage, it receives the drive signal from the discharge drive module 2 to activate the corresponding relay contacts in the relay array, physically or electronically switching the discharge voltage path and connecting the specified discharge voltage path to the discharge power unit 41. This ensures that different voltages can be called as needed during the self-test program, providing a basic condition for subsequent discharge current waveform acquisition, while avoiding the risk of short circuits between voltage paths.

[0048] The isolation unit 32 is used to prevent voltage interference during the switching of discharge voltage paths, ensuring that the discharge power unit 41 is driven to discharge under different discharge voltages. The isolation unit 32 uses an optocoupler or isolation transformer as its core component. Its function is to achieve electrical isolation during the switching of discharge voltage paths, preventing high-voltage interference, such as voltage spikes or ground noise, from affecting the low-voltage control signal, and ensuring stable and reliable driving of the discharge power unit 41 under different discharge voltages. When the relay array unit 31 switches between different discharge voltage paths, the isolation unit 32 completely isolates the signal controlling the switching of the discharge voltage path from the discharge voltage path through the optocoupler's photoelectric conversion or the transformer's magnetic isolation mechanism, thus eliminating common-mode interference. This ensures that the discharge waveform data acquired by the current acquisition module 6 is not affected by the switching transient, thereby improving the accuracy and reliability of the EDM self-test.

[0049] The transient suppression unit 33 is used to actively absorb voltage spikes and arc energy when switching discharge voltage paths. The transient suppression unit 33 includes a nonlinear resistor element 331 and an energy absorption circuit 332. The nonlinear resistor element 331 is used to suppress voltage spikes, with a varistor or TVS diode selected as the core component. The energy absorption circuit 332 is used to dissipate arc energy, with an RC snubber circuit or surge absorber selected as the core component. When the relay array unit 31 generates a voltage spike or arc during switching, the nonlinear resistor element 331 quickly conducts using its voltage-sensitive characteristics, clamping the voltage spike to a safe level. Simultaneously, the energy absorption circuit 332 dissipates the arc energy through a resistor-capacitor combination, converting it into heat energy. This maintains the stability of the discharge voltage path, ensuring that the acquisition of current waveforms driven by different voltages during self-testing is not affected by transient interference, thus improving the accuracy of health detection.

[0050] The discharge power module 4 is used to control the discharge power units 41 of different paths to perform discharge actions independently through drive signals, including multiple discharge power units 41 connected in parallel; each discharge power unit 41 includes a discharge resistor subunit 411 and a MOS switch subunit 412.

[0051] In this embodiment, the discharge resistor subunit 411 provides a fixed resistance value. A power resistor, such as a flat wire-wound resistor or a circular wire-wound resistor, is selected as the core component. Its function is to provide a discharge circuit with a fixed resistance value, converting electrical energy into heat energy to form a stable current load. During the discharge process, the resistor subunit is connected in series in the discharge circuit. Its resistance value, typically in the milliohm range, directly determines the peak value of the discharge current (B). Since the inductance and wiring method of the resistor significantly affect the current rise slope (C), a low-inductance resistor, such as a flat wire-wound resistor, must be selected, and the wiring layout optimized to improve discharge efficiency and reduce losses.

[0052] The MOS switching subunit 412 is used to control the discharge action through a drive signal, selecting a MOSFET power transistor and its drive circuit as the core device. Responding to the PWM drive signal from the discharge drive module 2, it controls the start / stop of the discharge action and the A-pulse width through rapid switching. The discharge drive module 2 sends a PWM signal to the gate of the MOSFET in the MOS switching subunit 412 to control its conduction and turn-off. When on, the discharge current flows through the resistor subunit to form a loop; when off, the current is cut off. The switching performance of the MOSFET, such as its response speed, directly affects the A-pulse width accuracy and C-rising edge slope of the current waveform. If an abnormal pulse width is detected during self-testing, it is necessary to check whether the MOSFET is damaged or whether the drive signal is interfered with.

[0053] The current transformer module 5 is used to acquire the discharge current signal of the discharge power unit 41 in real time.

[0054] In this embodiment, the current transformer module 5 selects the current transformer 51 and the signal output interface circuit as core components. Its function is to collect the discharge current signal of the discharge power unit 41 in real time and convert the large current greater than 10 amperes into a processable small current signal proportionally. The current transformer 51 converts the large primary current into a small secondary current in the milliampere level by sensing the current change in the discharge circuit through the magnetic core and based on the principle of electromagnetic induction. The output interface circuit transmits the discharge current signal to the current signal conversion unit 61 through a shielded cable to ensure accurate capture of characteristic parameters such as the peak value A, pulse width B, and rising edge slope C of the current waveform during the spark machine self-test, providing the original data basis for subsequent discharge performance comparison and analysis.

[0055] The current acquisition module 6 is used to convert the discharge current signal into discharge waveform data, including a current signal conversion unit 61 and a dynamic filtering unit 62.

[0056] In this embodiment, the current signal conversion unit 61 is used to convert the discharge current signal collected by the current transformer 51 into discharge waveform data. An operational amplifier and an ADC (Analog-to-Digital Converter) are selected as the core components. Its function is to convert the milliampere-level discharge current signal collected by the current transformer 51 into digitized discharge waveform data. The current transformer 51 converts the current in the discharge circuit into a current signal proportionally through the principle of magnetic induction. After amplification and offset compensation by the operational amplifier, the analog signal is converted into digital waveform data by an ADC with a sampling rate of 100kHz, retaining characteristics such as peak value, RMS value, and pulse width, providing the original data basis for subsequent analysis.

[0057] The dynamic filtering unit 62 is used to adjust the filtering parameters in real time based on the noise characteristics of the discharge waveform data and perform adaptive filtering processing. It is selected as the first digital signal processor and the adaptive filtering algorithm library as core components. Based on the noise characteristics of different discharge power units 41, such as MOSFET switching noise and power grid harmonic interference, it adjusts the filtering parameters in real time and performs adaptive filtering processing to ensure the purity and reliability of the discharge waveform data. The first digital signal processor first analyzes the spectral characteristics of the input discharge waveform data and dynamically matches a preset noise pattern library. Then, it calls adaptive algorithms, such as LMS filtering or wavelet denoising, to update the filtering parameters, such as cutoff frequency and order, to filter out interference in specific frequency bands in real time, such as switching noise greater than 10kHz, and finally outputs smooth current waveform data.

[0058] See attached document Figure 5In one implementation, the EDM system controller 1 triggers the EDM system discharge self-test program, sets the discharge conditions to "standard test voltage 120V, single-channel independent discharge, each channel discharge lasting 2s", and connects to the GATE board via EtherCAT communication; the CN4 interface of the GATE board connects to the MOS board to control the on / off state of each MOS transistor, and the CN5 interface of the GATE board connects to the voltage switching relay. The voltage switching relay controls the discharge voltage paths of four different voltages. The discharge power unit 41 is connected to the current transformer 51. The discharge circuit of the discharge power unit 41 is generally divided into 9 discharge power units 41 according to the current size: IP0.1, IP0.2, IP0.4, IP1, IP2, IP4, IP8, IP16, and IP32. The number after IP is the rated current of the discharge power unit 41. Each discharge power unit 41 has a fixed resistor. When different currents are required during discharge processing, different discharge power units 41 are combined to obtain the required rated current. However, the rated discharge current is not greater than the sum of the rated current values ​​of all discharge power units 41. For example, IP21 = IP16 + IP4 + IP1. When testing the current waveform, each discharge power unit 41 sequentially drives discharge power units 1-9 to discharge, with a 1-second interval between each discharge, under no-load conditions. Then, different voltages are used to drive the same power discharge unit to discharge; the voltage is the rated DC 120V. Each discharge current lasts for 2 seconds, and the discharge current waveform is generally a square wave alternating between ON and OFF states. The peak current is typically four times the rated current. Three current transformers 51 with different ranges are used for switching: 0A-5A, 5A-50A, and 50A-150A. The range of the current transformer 51 corresponds to the peak current of the discharge current. For example, in an IP32 circuit, the range corresponding to 32*4=128A is selected. The current acquisition module 6 and the EDM system controller 1 communicate via RS485 serial port protocol. During self-test, the EDM system controller 1 informs the current acquisition module 6 via RS485 serial port which discharge power unit 41 starts and ends discharging. When discharging begins, the corresponding range current transformer 51 is connected to the circuit, and the discharge waveform is acquired. When discharging ends, the acquisition of the discharge current waveform stops, and the current transformer 51 is disconnected. The sampling time is determined by the discharge duration, and the sampling frequency is 200K. The current transformer 51 is connected to the current acquisition module 6, and the current acquisition module 6 is connected to the EDM system controller 1 to achieve a closed-loop connection. The EDM system controller 1 calls the factory-calibrated standard current waveforms of the 9 discharge power units 41 and compares them using a similarity algorithm. A similarity of ≥92% between the discharge current waveform and the standard current waveform is set as qualified. The factory-calibrated standard voltage discharge current waveforms of the 4 voltage discharges are compared. The peak current magnitude is considered normal if the difference is within ±10%. Based on the voltage and current comparison results, the performance of the discharge power unit 41 is judged, and a test report is obtained.

[0059] See attached document Figure 6 The following is a description of another embodiment of the method and system provided in this application.

[0060] Based on the spark discharge health detection device described in Embodiment 1, this Embodiment 2 adds some specific implementation methods.

[0061] In this embodiment, the transient suppression unit 33 further includes a mode prediction subunit 333 and a collaborative optimization subunit 334.

[0062] Among them, the pattern prediction subunit 333 is used to establish a dynamic behavior model of voltage spikes and arc energy based on the feature comparison results, and obtain prediction results based on the dynamic behavior model; the prediction results include the occurrence probability and intensity pattern of voltage spikes and arc energy.

[0063] The pattern prediction subunit 333 selects an embedded microprocessor and a behavioral modeling algorithm library as its core components. Its function is to establish a dynamic behavioral model of voltage spikes and arc energy based on the comparison results of historical discharge waveform characteristics, such as voltage spike amplitude and arc duration, and output the prediction results, namely the probability and intensity pattern of occurrence. The embedded microprocessor analyzes the historical data of the current acquisition module 6 to extract the spatiotemporal characteristics of transient interference, such as spike rise time and energy spectrum distribution; it uses machine learning algorithms, such as LSTM neural networks, to build a dynamic behavioral model and predict in real time the intensity and probability distribution of transient interference that may be generated under different operating conditions, such as 120V voltage switching. For example, during high voltage switching, there is a 90% probability of a spike >200V / μs, providing data support for collaborative suppression.

[0064] The collaborative optimization subunit 334, connected to the mode prediction subunit 333, is used to dynamically coordinate the conduction threshold of the nonlinear resistive element 331 and the energy distribution strategy of the energy absorption circuit 332 based on the prediction results.

[0065] The collaborative optimization subunit 334 selects a programmable logic device, such as an FPGA, and a dynamic parameter adjustment circuit as core components to dynamically coordinate the turn-on threshold of the nonlinear resistor element 331 and the energy distribution strategy of the energy absorption circuit 332 based on the mode prediction results. The FPGA receives the peak probability / intensity data output by the mode prediction subunit 333, such as "strong arc risk," and calculates the optimal suppression strategy in real time—for high-probability strong peaks, it automatically reduces the turn-on threshold of the nonlinear resistor element 331 to 150V (default 200V) to clamp it in advance; at the same time, it adjusts the capacitor charging and discharging rate of the energy absorption circuit 332, for example, by increasing the discharge current to 5A, to ensure that the arc energy is dissipated within microseconds. This dynamic coordination improves transient suppression efficiency and significantly reduces the risk of MOSFET breakdown.

[0066] The collaborative optimization subunit 334 is also connected to the discharge drive module 2 to obtain the timing characteristics of the drive signal and optimize the update frequency of the dynamic behavior model based on these characteristics, thereby realizing the adaptive collaborative control of the transient suppression unit 33. The collaborative optimization subunit 334 is connected to the discharge drive module 2 via a high-speed communication interface, such as SPI. Its core function is to optimize the update frequency of the dynamic behavior model based on the timing characteristics of the drive signal. The FPGA analyzes the pulse width, period, and rising edge characteristics of the drive signal in real time, such as the MOSFET switching timing. When a high-frequency switching mode is detected, such as continuous testing of four voltage channels, the behavior model update frequency is increased from 10Hz to 1kHz; during the stable discharge phase, it is reduced to 100Hz. This adaptive update mechanism ensures that the dynamic behavior model always matches the actual operating conditions, reducing the prediction error rate and also reducing processor power consumption.

[0067] In this embodiment, the EDM discharge health detection device also includes an adaptive calibration module 7; the adaptive calibration module 7 is connected to the EDM system controller 1 and is used to dynamically update the standard waveform database based on the discharge waveform data from multiple detections, so as to adapt to the parameter differences of the components of the discharge power unit 41 in different paths.

[0068] The adaptive calibration module 7 includes a coefficient of variation analysis unit 71, an aging attenuation compensation unit 72, and a lifetime prediction unit 73.

[0069] The coefficient of variation analysis unit 71 is used to dynamically adjust the update threshold of the standard waveform database based on the dispersion of discharge waveform data. It selects a second digital signal processor and a statistical analysis algorithm library as core components. Its function is to dynamically adjust the update threshold of the standard waveform database based on the dispersion of multiple discharge waveform data, such as the fluctuation range of peak current. The second digital signal processor calculates the coefficient of variation of historical waveform data, such as the standard deviation of peak current divided by the average value. When the coefficient of variation exceeds a preset threshold, such as 10%, the similarity comparison range is automatically widened, for example, from 92% to 90%, to accommodate the natural drift of component parameters, such as differences between different resistor batches. This avoids misjudgments caused by excessively high data dispersion, ensuring that the self-test results are more consistent with actual operating conditions.

[0070] The aging attenuation compensation unit 72 is used to calculate the attenuation coefficient based on the usage time of the discharge power unit 41 and the historical waveform data of the coefficient of variation analysis unit 71, and to dynamically correct the update threshold of the standard waveform database. It selects a real-time clock module and an attenuation model algorithm as core components. Its function is to calculate the attenuation coefficient of components based on the usage time of the discharge power unit 41, such as the cumulative discharge hours and the dispersion of the standard waveform data, for example, the increase in resistance due to resistor aging, and to dynamically correct the update threshold of the standard waveform database. The real-time clock module records the operating time of the discharge power unit 41. Simultaneously, the second digital signal processor, combined with the discrete data from the coefficient of variation analysis unit 71, uses a linear regression model to calculate the attenuation coefficient, for example, a 1% increase in resistance every 1000 hours. Subsequently, the attenuation model algorithm automatically adjusts the parameter range of the standard waveform data, for example, expanding the allowable deviation of the peak current from ±10% to ±12%, compensating for the effects of aging and preventing the EDM self-test from misjudging normal aging as a fault.

[0071] The lifespan prediction unit 73 calculates the remaining lifespan of the discharge power unit 41 based on the attenuation coefficient and dispersion, and outputs the prediction result to the EDM system controller 1. It selects a machine learning coprocessor and data output interface as core components. Its function is to calculate the remaining lifespan of the discharge power unit 41 based on the attenuation coefficient provided by the aging attenuation compensation unit 72 and the dispersion of the coefficient of variation analysis unit 71, and output the prediction result to the EDM system controller 1. The coprocessor integrates attenuation coefficients, such as the resistance change rate, and discrete data, such as the peak fluctuation range, and applies lifespan models, such as the Weibull distribution algorithm, to predict the remaining lifespan, such as "500 hours remaining." The prediction result is transmitted in real time to the EDM system controller 1 interface for display or storage, helping users plan maintenance in advance and reduce unexpected downtime.

[0072] In this embodiment, the EDM system controller 1 is also used to automatically trigger an additional self-test program based on the remaining service life prediction result; when the remaining service life prediction result is lower than the preset service life threshold, the EDM system controller 1 re-executes the discharge self-test program and updates the feature comparison result and the test report.

[0073] The EDM system controller 1 receives lifetime prediction data via an internal bus. When it detects that the remaining lifetime prediction value of a certain discharge power unit 41 is lower than a preset threshold, it automatically triggers an additional self-test program. First, it sets the discharge condition to "standard test voltage 120V, single-channel independent discharge, each channel discharge lasting 2s". Then, it controls the discharge drive module 2 to activate the target discharge power unit 41 to discharge sequentially. The current acquisition module 6 captures the current waveform through the current transformer 51 at a sampling rate of 100kHz. After processing by the dynamic filtering unit 62, it extracts feature values ​​such as A pulse width, B peak value, and C rising edge slope. It calls the standard waveform database and uses a similarity algorithm to compare feature values, such as dynamic fitting interval technology, allowing ±10% fluctuation. If the similarity is lower than 90%, it marks the discharge performance as abnormal. Finally, it generates an updated test report, which includes the revised feature comparison results, such as a 20% decrease in peak current and targeted maintenance suggestions, such as replacing resistors and checking wiring. The report is stored in the system's non-volatile memory with a version number identifier and pushed to the HMI interface for early warning.

[0074] It should be further explained that the life prediction unit 73 uses the Weibull distribution algorithm for modeling, and the input parameters integrate the attenuation coefficient of the aging attenuation compensation unit 72 and the discrete data of the coefficient of variation analysis unit 71 to ensure prediction accuracy. The additional self-test program reuses the original hardware resources of the EDM machine, such as the discharge drive module 2 and the current transformer 51, and avoids conflicts with the periodic self-test by scheduling the process through the state machine embedded in the EDM system controller 1. The feature comparison process combines the extended allowable deviation of the aging attenuation compensation unit 72, such as ±12%, to prevent misjudging normal aging. The report update mechanism retains historical records for trend analysis and outputs early warnings in real time through the EDM system controller 1 to ensure that the technical solution is fully disclosed and logically sound.

[0075] This application also provides a spark discharge health detection method, applied to the apparatus of any of the above embodiments, with reference to... Figure 7 It illustrates a flowchart of a method provided in an embodiment of this application, the method comprising steps S1-S7: S1. The discharge self-test program is executed and the discharge control command is output through the EDM system controller 1.

[0076] S2. The discharge drive module 2 receives the discharge control command and generates the drive signal.

[0077] S3. Through the voltage switching relay module 3, different discharge voltage paths are switched in response to the drive signal to drive the discharge power module 4 to discharge.

[0078] S4. The discharge power module 4 uses a drive signal to control the discharge power unit 41 to independently perform the discharge action.

[0079] S5. The discharge current signal of the discharge power unit 41 is collected in real time through the current transformer module 5.

[0080] S6. The discharge current signal is converted into discharge waveform data through the current acquisition module 6.

[0081] S7. The discharge waveform data is received through the EDM system controller 1, and the discharge waveform data is compared with the preset standard waveform data to obtain the feature comparison result. Based on the feature comparison result, the performance status of the discharge power unit 41 and the status of the discharge voltage path are determined, and a test report is output.

[0082] Unless otherwise defined, the technical or scientific terms used in this application shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," "third," and similar terms used in this application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. The terms "an" or "a" and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising" or "including" and similar terms mean that the elements or objects preceding "comprising" or "including" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. "Above," "below," "left," "right," etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0083] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A spark machine discharge health detection device, characterized in that: It includes a spark machine system controller (1), a discharge drive module (2), a voltage switching relay module (3), a discharge power module (4), a current transformer module (5), and a current acquisition module (6); The EDM system controller (1) is used to execute the discharge self-test program and output discharge control commands; The discharge drive module (2) is connected to the EDM system controller (1) and is used to receive the discharge control command and generate a drive signal; The voltage switching relay module (3) is connected to the discharge drive module (2) and is used to switch different discharge voltage paths in response to the drive signal so as to drive the discharge power module (4) to discharge through different discharge voltages. The discharge power module (4) includes multiple parallel discharge power units (41), which are respectively connected to the discharge drive module (2) and the voltage switching relay module (3), and are used to control the discharge power units (41) of different paths to independently perform discharge actions through the drive signal; The current transformer module (5) is installed in the discharge circuit of each discharge power unit (41) and is used to collect the discharge current signal of the discharge power unit (41) in real time. The current acquisition module (6) is connected to the current inductance module (5) and is used to convert the discharge current signal into discharge waveform data. The spark machine system controller (1) is also used to receive the discharge waveform data transmitted by the current acquisition module (6), and compare the discharge waveform data with the preset standard waveform data to obtain the feature comparison result; Based on the feature comparison results, determine the performance status of each discharge power unit (41) and the status of the discharge voltage path, and output a detection report.

2. The spark machine discharge health detection device according to claim 1, characterized in that: The EDM system controller (1) includes a discharge self-test execution unit (11) and a waveform comparison and analysis unit (12); The discharge self-test execution unit (11) is used to execute the discharge self-test program and output discharge control commands; The waveform comparison and analysis unit (12) is used to receive the discharge waveform data transmitted by the current acquisition module (6), and perform feature comparison and analysis between the discharge waveform data and the preset standard waveform data to obtain the feature comparison result.

3. The spark machine discharge health detection device of claim 1, wherein: The voltage switching relay module (3) includes a relay array unit (31), an isolation unit (32), and a transient suppression unit (33); The relay array unit (31) is used to switch different discharge voltage paths in response to the drive signal; The isolation unit (32) is used to prevent voltage interference during the switching of the discharge voltage path and to ensure that the discharge power module (4) is driven to discharge by different discharge voltages. The transient suppression unit (33) is used to actively absorb voltage spikes and arc energy when switching the discharge voltage path; wherein, the transient suppression unit (33) includes a nonlinear resistor element (331) and an energy absorption circuit (332), the nonlinear resistor element (331) is used to suppress the voltage spikes, and the energy absorption circuit (332) is used to dissipate the arc energy.

4. The spark gap discharge health detection apparatus of claim 3, wherein: The transient suppression unit (33) further includes a mode prediction subunit (333) and a collaborative optimization subunit (334); The pattern prediction subunit (333) is used to establish a dynamic behavior model of the voltage spike and the arc energy based on the feature comparison results, and to obtain prediction results based on the dynamic behavior model; the prediction results include the occurrence probability and intensity pattern of the voltage spike and the arc energy. The collaborative optimization subunit (334) is connected to the mode prediction subunit (333) and is used to dynamically coordinate the conduction threshold of the nonlinear resistive element (331) and the energy distribution strategy of the energy absorption circuit (332) according to the prediction result. The collaborative optimization subunit (334) is also connected to the discharge drive module (2) to obtain the timing characteristics of the drive signal and optimize the update frequency of the dynamic behavior model based on the timing characteristics, thereby realizing the adaptive collaborative control of the transient suppression unit (33).

5. The spark gap discharge health detection apparatus of claim 1, wherein: The discharge power module (4) includes multiple parallel discharge power units (41); each discharge power unit (41) includes a discharge resistor subunit (411) and a MOS switch subunit (412); The discharge resistor subunit (411) is used to provide a fixed resistance value; The MOS switch subunit (412) is used to control the discharge action through the drive signal.

6. The spark gap discharge health detection apparatus of claim 1, wherein: The current acquisition module (6) includes a current signal conversion unit (61) and a dynamic filtering unit (62); The current signal conversion unit (61) is used to convert the discharge current signal collected by the current inductance module (5) into discharge waveform data. The dynamic filtering unit (62) is used to adjust the filtering parameters in real time based on the noise characteristics of the discharge waveform data and perform adaptive filtering processing. The dynamic filtering unit (62) uses a digital signal processor to dynamically update the filtering parameters in order to match the noise modes of the discharge power units (41) of different paths.

7. The spark gap discharge health detection apparatus of claim 1, wherein: It also includes an adaptive calibration module (7); the adaptive calibration module (7) is connected to the EDM system controller (1) and is used to dynamically update the standard waveform database based on the discharge waveform data detected multiple times, so as to adapt to the parameter differences of the components of the discharge power unit (41) in different paths.

8. The spark gap discharge health detection apparatus of claim 7, wherein: The adaptive calibration module (7) includes a coefficient of variation analysis unit (71), an aging attenuation compensation unit (72), and a life prediction unit (73); The coefficient of variation analysis unit (71) is used to dynamically adjust the update threshold of the standard waveform database based on the dispersion of the discharge waveform data; The aging attenuation compensation unit (72) is used to calculate the attenuation coefficient of the component based on the usage time of the discharge power unit (41) and the degree of dispersion, and to dynamically correct the update threshold of the standard waveform database. The lifetime prediction unit (73) is used to calculate the remaining lifetime of the discharge power unit (41) based on the attenuation coefficient and the degree of dispersion, and output the remaining lifetime prediction result through the EDM system controller (1).

9. The spark gap discharge health detection apparatus of claim 8, wherein: The EDM system controller (1) is also used to automatically trigger an additional self-test program based on the remaining service life prediction result; when the remaining service life prediction result is lower than the preset service life threshold, the EDM system controller (1) re-executes the discharge self-test program and updates the feature comparison result and the test report.

10. A method of spark machine discharge health detection, the method comprising: The method applied to the EDM discharge health detection device according to any one of claims 1 to 9 includes the following steps: ​ S1. The discharge self-test program is executed and the discharge control command is output through the EDM system controller (1); S2. The discharge control command is received and a drive signal is generated through the discharge drive module (2); S3. By switching different discharge voltage paths in response to the drive signal through the voltage switching relay module (3), the discharge power module (4) is driven to discharge. S4. The discharge power module (4) uses the drive signal to control the discharge power unit (41) to independently perform the discharge action. S5. The discharge current signal of the discharge power unit (41) is collected in real time through the current transformer module (5). S6. The discharge current signal is converted into discharge waveform data through the current acquisition module (6); S7. The discharge waveform data is received by the EDM system controller (1), and the discharge waveform data is compared with the preset standard waveform data to obtain the feature comparison result. Based on the feature comparison result, the performance status of the discharge power unit (41) and the status of the discharge voltage path are determined, and a detection report is output.

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