New wire protection method for wire electrical discharge machining based on accumulated machining state timing
Patent Information
- Application Number
- CN202611152364.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-31
- Publication Date
- 2026-11-03
AI Technical Summary
In wire electrical discharge machining, using high current and high energy parameters directly after replacing the wire can easily lead to wire breakage. Furthermore, the operator is highly dependent on the wire, and existing protection methods cannot effectively reduce the risk of wire breakage, especially in scenarios with frequent pauses or idle periods where the protection time is inaccurate.
A new wire protection method based on cumulative timing during machining is adopted. It automatically keeps track of time during actual machining, accumulates protection time only when the machine tool is in machining state, forces parameter adjustment to ensure uninterrupted parameter switching process, and confirms the release of protection through verification information, thereby reducing misoperation.
The system achieves automated new filament protection, reduces the risk of filament breakage, improves processing stability and continuity, reduces waste generation, and enhances operational safety.
Smart Images
Figure CN123024946A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wire electrical discharge machining technology, and more specifically to a method for protecting new wires in wire electrical discharge machining based on cumulative timing of machining status. Background Technology
[0002] In wire electrical discharge machining (EDM), the electrode wire is a consumable. After replacing the electrode wire with a brand new one, the surface of the new wire is smooth. If high current and high energy parameters are used directly at this time, the new wire is prone to premature breakage due to excessive current, causing machining interruption and affecting machining efficiency. At the same time, the surface of the new wire may be unevenly ablated under excessive discharge energy, resulting in a decrease in subsequent machining accuracy. In addition, if the operator forgets or neglects to adjust the machining parameters in time after changing the wire and directly uses the conventional high current parameters, the above problems will be exacerbated.
[0003] Currently, common practices in the industry include the following: relying on operator self-awareness, manually lowering the current after wire replacement, processing for a period of time, and then manually adjusting it back. The drawback of this method is its heavy reliance on operator experience and responsibility, the risk of forgetting, and the lack of automation. Some systems allow preset new wire parameter schemes, but operators still need to actively switch before processing, and there is no automatic timing recovery mechanism, resulting in a poor user experience. If parameters are simply locked using a fixed absolute countdown, the lock time will expire prematurely in scenarios with frequent pauses, stops, idle periods, and retries, failing to achieve a protection effect corresponding to the actual processing load. Therefore, a new wire protection control method is needed that can automatically force protection, time only during actual processing, and ensure uninterrupted switching. Summary of the Invention
[0004] The purpose of this invention is to provide a new wire protection method for wire EDM based on cumulative timing of processing status. This method can realize the automatic time locking of processing parameters after wire change, and the timing is only during actual processing. It can take effect immediately during parameter switching, which helps to reduce the risk of new wire breakage and improve processing stability.
[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for protecting new wire in wire electrical discharge machining based on cumulative timing of machining status includes: Step 1: Receive the protection time value set by the operator through the input interface, and receive a set of protection processing parameter values selected by the operator from the preset processing parameters or directly input by the operator; Step 2: Within the time interval defined by the protection time value, when the controller is executed to acquire processing parameters, it is determined whether the processing parameters to be acquired belong to the pre-divided collision parameter category, wherein the collision parameter category refers to the set of parameters used for workpiece coordinate positioning and set to be unaffected by the forced parameter protection mechanism. Step 3: If it is determined that the current processing parameter to be acquired belongs to the collision parameter category, then return the current actual setting value of the processing parameter to the processing execution unit; Step 4: If it is determined that the current processing parameter to be acquired does not belong to the collision parameter category, then the protected processing parameter value is forcibly returned to the processing execution unit to replace the current actual setting value of the processing parameter; Step 5: During the forced return execution, the controller detects the working status of the machine tool and starts and continuously accumulates the time only when it detects that the machine tool is in the machining execution state. This accumulated time is used to measure the actual machining time that has occurred during the forced protection. Step 6: When the accumulated time reaches the protection time value, the operation of forcibly returning to the protected processing parameter value is released, and the forced replacement will no longer be performed when obtaining processing parameters thereafter.
[0006] Furthermore, in step 1, after receiving the protection time value and the protection machining parameter value, the controller immediately enters the locked state. When entering the locked state, if it is detected that the machine tool is currently in the machining execution state, the parameter reload mechanism is immediately triggered to switch the current machining parameter to the protection machining parameter value in real time.
[0007] Furthermore, in step 1, after receiving the protection time value and the protection processing parameter value, the controller also includes: The protection time value and protection processing parameter value are serialized into a data file and saved to a non-volatile storage medium; When the controller is started again and re-enters the new wire protection settings interface, the previously saved protection time value and protection processing parameter value will be automatically loaded and displayed as the default settings.
[0008] Further, in step 2, it is determined whether the processing parameter to be acquired belongs to a pre-defined category of collision parameters, specifically: The type identifier bit allocated inside the controller is read from the current processing parameter to be acquired. When the type identifier bit matches the identifier bit that is pre-marked as the category of the collision parameter, it is determined that the parameter belongs to the category of the collision parameter.
[0009] Furthermore, in step 5, during the cumulative timing process, when it is detected that the machine tool processing state has changed to any one of pause, stop or idle, the elapsed time slice from the start of this timing or the last pause and resumption of timing to the current time is calculated, and the remaining protection time is updated. The remaining protection time is the protection time value minus the sum of all elapsed time slices. At the same time, the timing is paused until the machine tool is detected to enter the machining execution state again, at which point the timing will continue to accumulate from the updated remaining protection duration.
[0010] Furthermore, in step 6, when the accumulated time reaches the protection time value and the forced return operation is released, if it is detected that the machine tool is currently in the machining execution state, the parameter reload mechanism is immediately triggered to restore the current machining parameters to the latest non-protection setting value before entering the forced protection state.
[0011] Furthermore, the method also includes: Step 7: Receive the operator's proactive early release instruction; Step 8: In response to the proactive early release instruction, a verification information input interface pops up to obtain the verification information entered by the operator; Step 9: Compare the obtained verification information with the pre-stored unlock verification information. If the comparison results are consistent, immediately terminate the operation of forcibly returning the protection processing parameter value and clear the accumulated timer.
[0012] Furthermore, in step 9, if the machine tool is detected to be currently in a machining execution state when the forced return operation is immediately terminated, the parameter reload mechanism is immediately triggered to restore the current machining parameters to the latest non-protection setting value before entering the forced protection state.
[0013] In summary, the present invention has the following beneficial technical effects: 1. Facilitates automated protection: After changing the yarn, by setting the protection time and protection processing parameters, the system automatically forces the non-collision number parameters to be replaced with protection parameters within the protection period, reducing reliance on operator self-awareness and helping to reduce the risk of new yarn breakage.
[0014] 2. Timing is closer to actual processing conditions: Accumulated timing is only performed when the machine tool is actually in the processing state. Timing is not performed during pauses, stops, or idle periods, so that the protection duration can correspond to the actual processing load and avoid the protection time being exhausted prematurely due to frequent start and stop.
[0015] 3. Seamless parameter switching process: When the lock is active, automatically expires, or is manually unlocked, if the machine tool is processing, the parameters can be switched instantly through the parameter reload mechanism without waiting for the current processing segment to end. This helps reduce the probability of scrap and maintain processing continuity.
[0016] 4. Compatibility of touch count / tool setting functions: The touch count parameter category is classified as a set of parameters that are not affected by the forced parameter protection mechanism. During the protection period, the touch count parameter still returns the actual set value, so that the workpiece coordinate positioning function can be used normally, improving the continuity of operation.
[0017] 5. Enhanced protection against accidental operation: When proactively disabling protection in advance, confirmation information is required, reducing the possibility of premature protection disabling due to accidental button touch, and improving the operational safety of the system. Attached Figure Description
[0018] Figure 1 For this purpose bright Method flowchart; Figure 2 This is a schematic diagram of the timing state machine during the time-locked period. Detailed Implementation
[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.
[0020] like Figure 1 and Figure 2 As shown, this invention provides a new wire protection method for wire EDM based on cumulative timing of machining status. This method runs on the controller of the wire EDM machine. The controller is built on an STM32 and Linux system and is responsible for real-time control of the machine's machining process. The controller includes a processor and a memory. The memory stores a computer program, and the processor executes this program to implement the various steps of this method.
[0021] The controller's software layer includes the following functional modules that work together: The UI module provides a "New Silk Protection" button displayed on the screen. In the unlocked state, clicking this button opens a parameter editing window; in the locked state, clicking the button pops up a password confirmation unlock window to prevent accidental operation. The button displays the protection status in real time and shows a countdown based on the remaining protection time in the format "Protecting MM:SS".
[0022] The parameter storage module is responsible for serializing the protection time value and protection processing parameter value set by the operator in JSON format and persistently storing them in non-volatile storage media (such as a Flash file system). The next time the controller starts up and re-enters the Xinsi protection settings interface, it automatically loads the previously saved data as the default settings, reducing repetitive input.
[0023] The message-driven control module defines the message type MC_LOCK_CUT_PARAM_BY_TIME, which decouples communication between the UI layer and the motion control layer through a message queue. When the operator confirms the setting of the lock or manually unlocks it in advance, the instructions and parameters are passed to the motion control core through this message.
[0024] The lock status data structure maintains a set of variables in memory to record the current status of the new wire protection. Specifically, it includes: `cut_param_locked_by_time` (boolean), indicating whether the current state is locked; `cut_param_lock_accumulating` (boolean), indicating whether the current timer is accumulating; `cut_param_lock_start_tick` (uint32_t), recording the timestamp of the start of the current timer cycle; `cut_param_lock_duration_sec` (uint32_t), recording the lock duration set by the operator in seconds; and `cut_param_lock_data` (void pointer), pointing to a copy of the locked protection processing parameter data.
[0025] The parameter overriding module is invoked each time a processing execution component (such as a pulse power supply) requests processing parameters. This module reads the lock status data structure. If the current state is locked, it further determines whether the requested parameter is a non-touch parameter. If it is a non-touch parameter, it forces the return of the protected processing parameter value; if it is a touch parameter, it returns the current actual set value of the parameter.
[0026] The timed check and automatic release module runs periodically in the main control loop. When it detects that the system is in the cumulative timer state, it calculates the elapsed time. If the elapsed time reaches or exceeds the lock duration, it automatically sets the lock state to unlock, releases the parameter memory, and triggers parameter reload via a message to achieve automatic expiration and release.
[0027] In this invention, the processing parameters within the controller are pre-classified into two categories: touch-number parameters and ordinary processing parameters. Touch-number parameters refer to high-frequency parameters used for workpiece coordinate positioning (such as tool setting and alignment), such as a complete set of high-frequency discharge parameters including processing current, pulse width, and pulse interval. The difference is that the high-frequency discharge parameters in touch-number parameters typically use specific set values with extremely low energy to prevent strong discharge between the electrode wire and the workpiece during positioning, which could damage the surface. These parameters require the operator's set values to be maintained throughout the entire processing preparation period to ensure positioning accuracy. To this end, the controller assigns a type identifier bit to each processing parameter. By reading this identifier bit and comparing it with the identifier bit pre-marked as a touch-number parameter category, it can be determined whether the parameter belongs to the touch-number parameter category. Except for touch-number parameters, the other ordinary processing parameters that are effective during the formal processing stage are forcibly overwritten during the protection period.
[0028] The specific execution steps of this method are detailed below, including: Step 1: Receive settings.
[0029] After replacing the wire, the operator clicks the "New Wire Protection" button on the processing interface. The controller responds to the click, and a "New Wire Lock Processing Parameters" editing window pops up via the UI module. In this window, the operator sets the protection time value (selectable range 1~120 minutes, default 60 minutes) and a set of conservative protection processing parameter values (such as a smaller processing current, moderate pulse width, etc.). The operator can choose from preset schemes or directly enter values. After setting, the operator confirms, and the controller performs the following actions: The parameter storage module serializes the protection time value and the protection processing parameter value into a data file and saves it to a non-volatile storage medium; The message-driven control module constructs an MC_LOCK_CUT_PARAM_BY_TIME message, carrying the lock flag, duration, and various parameter data; After receiving the message, the motion control layer allocates memory and copies data to protect the processing parameters, sets cut_param_locked_by_time to true, and records cut_param_lock_duration_sec as the set number of seconds, and the controller enters the locked state. Meanwhile, the motion control layer detects the current state of the machine tool. If it is in the machining execution state, it immediately triggers the parameter reload mechanism, instantly switching all non-collision machining parameters to protected machining parameter values, achieving instant switching of locking effect; at this time, the machining will not be interrupted.
[0030] Step 2: Classification determination during parameter acquisition.
[0031] Within the time interval defined by the protection time value, the parameter overriding module intervenes each time the processing execution unit needs to obtain processing parameters. The module first reads the lock status data structure. If cut_param_locked_by_time is false, it directly returns the actual parameter setting value; if it is true, it reads the type flag bit of the parameter to be obtained. If the type flag bit matches the flag bit pre-marked as the category of the touch-sensitive parameter, it is determined that the parameter belongs to the touch-sensitive parameter category; otherwise, it is determined to be a non-touch-sensitive parameter.
[0032] Step 3: Handling of collision parameter exemption.
[0033] If the machining parameter to be acquired is determined to be a collision parameter, the parameter overriding module returns the current actual setting value of the parameter to the machining execution component, unaffected by the protection lock. This ensures that the workpiece coordinate positioning (collision / tool setting) function is normally available during the protection period.
[0034] Step 4: Force overwrite of non-touch parameter.
[0035] If it is determined that the processing parameter to be acquired does not belong to the collision parameter category, the parameter overriding module reads the corresponding protected processing parameter value from cut_param_lock_data and forcibly returns the protected value to the processing execution unit to replace the original actual setting value of the parameter. In this way, any commands such as processing current and pulse width are limited to a conservative range.
[0036] Step 5: Conditional timing control.
[0037] During forced return execution, the controller continuously monitors the machine tool's operating status. When it detects that the machine tool's pulse power is on and the table feed is valid, indicating entry into the machining execution state, the controller checks the lock status. If `cut_param_locked_by_time` is true and `cut_param_lock_accumulating` is false, the current system timestamp is recorded as `cut_param_lock_start_tick`, and `cut_param_lock_accumulating` is set to true to begin accumulating the time. This accumulating time only measures the actual machining time that has occurred during forced protection.
[0038] During processing, if the machine tool switches to any of the paused, stopped, or idle states due to operator pause, threading failure retry, or workpiece inspection, the controller immediately calculates the elapsed time slices from the start of this timing or the last pause resumed timing to the current moment, and updates the remaining protection duration. The remaining protection duration is calculated by subtracting the sum of all elapsed time slices from the protection time value. Simultaneously, `cut_param_lock_accumulating` is set to false, pausing the timing. When the machine tool re-enters the processing execution state, the controller re-records the new `cut_param_lock_start_tick` and restores `cut_param_lock_accumulating` to true, resuming the accumulating timing from the updated remaining protection duration. The state transition logic is as follows: The unlocked state transitions to the locked, untimed state after being set by the operator; the processing start signal triggers the start of timing, entering the timing state; processing pause / stop triggers a timing pause, during which no timing occurs; processing resumes and re-enters the timing state; when the accumulated time reaches the set value or a manual unlock command is received, it transitions back to the unlocked state.
[0039] Step 6: Automatic expiration and cancellation.
[0040] The timed check and automatic release module continuously compares the currently accumulated processing time (calculated based on the difference between cut_param_lock_start_tick and the current timestamp, and the recorded remaining time) with the size of cut_param_lock_duration_sec in the main loop. When the accumulated time reaches the protection time value, the module performs an automatic release operation. Set cut_param_locked_by_time to false and release the memory pointed to by cut_param_lock_data; Set cut_param_lock_accumulating to false and clear the relevant timing variables; At this point, the forced return of protected machining parameter values is lifted, and forced replacement will no longer be performed when retrieving machining parameters thereafter. If the machine tool is detected to be in the processing state at this time, the parameter reload mechanism is immediately triggered to restore the current processing parameters to the latest non-protection setting value before entering the forced protection state (i.e., the normal operating parameters of the operator), so as to achieve seamless switching of automatic expiration.
[0041] In addition, this method also includes a manual pre-unlocking process, as detailed below: Step 7: Receive the operator's proactive early release command. During the protection period, the operator can issue this command by clicking the "New Silk Protection" button, which is in the locked state.
[0042] Step 8: In response to the proactive early release command, a verification information input interface pops up, such as a password input dialog box, prompting the operator to enter the unlock password. The controller obtains the verification information entered by the operator.
[0043] Step 9: The controller compares the acquired verification information with the pre-stored unlock verification information (e.g., the numbers "1234"). If the comparison results match, the forced return to the protected machining parameter value is immediately terminated, and the accumulated timer is reset to zero. If the machine tool is detected to be in machining execution state during this process, the parameter reload mechanism is immediately triggered, instantly restoring the current machining parameters to the latest non-protected setting value before entering the forced protection state, thus achieving immediate manual unlocking. If the password comparison does not match, an error message is displayed, and the protected lock state is maintained.
[0044] Embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) that include computer-usable program code.
[0045] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.
[0046] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.
[0047] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.
[0048] Contents not described in detail in this specification are prior art known to those skilled in the art. It is hereby indicated that the above description is intended to help those skilled in the art understand this invention, but does not limit the scope of protection of this invention. Any equivalent substitutions, modifications, improvements, or simplifications of the above descriptions that do not depart from the essential content of this invention fall within the scope of protection of this invention.
Claims
1. A method for protecting new wire in wire electrical discharge machining based on cumulative timing of machining status, characterized in that, include: Step 1: Receive the protection time value set by the operator through the input interface, and receive a set of protection processing parameter values selected by the operator from the preset processing parameters or directly input by the operator; Step 2: Within the time interval defined by the protection time value, when the controller is executed to acquire processing parameters, it is determined whether the processing parameters to be acquired belong to the pre-divided collision parameter category, wherein the collision parameter category refers to the set of parameters used for workpiece coordinate positioning and set to be unaffected by the forced parameter protection mechanism. Step 3: If it is determined that the current processing parameter to be acquired belongs to the collision parameter category, then return the current actual setting value of the processing parameter to the processing execution unit; Step 4: If it is determined that the current processing parameter to be acquired does not belong to the collision parameter category, then the protected processing parameter value is forcibly returned to the processing execution unit to replace the current actual setting value of the processing parameter; Step 5: During the forced return execution, the controller detects the working status of the machine tool and starts and continuously accumulates the time only when it detects that the machine tool is in the machining execution state. This accumulated time is used to measure the actual machining time that has occurred during the forced protection. Step 6: When the accumulated time reaches the protection time value, the operation of forcibly returning to the protected processing parameter value is released, and the forced replacement will no longer be performed when obtaining processing parameters thereafter.
2. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 1, characterized in that, In step 1, after receiving the protection time value and the protection machining parameter value, the controller immediately enters the locked state. When entering the locked state, if it is detected that the machine tool is currently in the machining execution state, the parameter reload mechanism is immediately triggered to switch the current machining parameter to the protection machining parameter value in real time.
3. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 2, characterized in that, In step 1, after receiving the protection time value and the protection processing parameter value, the controller also includes: The protection time value and protection processing parameter value are serialized into a data file and saved to a non-volatile storage medium; When the controller is started again and re-enters the new wire protection settings interface, the previously saved protection time value and protection processing parameter value will be automatically loaded and displayed as the default settings.
4. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 3, characterized in that, In step 2, it is determined whether the processing parameter to be acquired belongs to the pre-defined collision parameter category, specifically: The type identifier bit allocated inside the controller is read from the current processing parameter to be acquired. When the type identifier bit matches the identifier bit that is pre-marked as the category of the collision parameter, it is determined that the parameter belongs to the category of the collision parameter.
5. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 4, characterized in that, In step 5, during the cumulative timing process, when the machine tool processing state is detected to change to any one of pause, stop, or idle, the elapsed time slice from the start of this timing or the last pause and resumption of timing to the current moment is calculated, and the remaining protection time is updated. The remaining protection time is the protection time value minus the sum of all elapsed time slices. At the same time, the timing is paused until the machine tool is detected to enter the machining execution state again, at which point the timing will continue to accumulate from the updated remaining protection duration.
6. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 5, characterized in that, In step 6, when the accumulated time reaches the protection time value and the forced return operation is released, if it is detected that the machine tool is currently in the machining execution state, the parameter reload mechanism is immediately triggered to restore the current machining parameters to the latest non-protection setting value before entering the forced protection state.
7. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 6, characterized in that, The method further includes: Step 7: Receive the operator's proactive early release instruction; Step 8: In response to the proactive early release instruction, a verification information input interface pops up to obtain the verification information entered by the operator; Step 9: Compare the obtained verification information with the pre-stored unlock verification information. If the comparison results are consistent, immediately terminate the operation of forcibly returning the protection processing parameter value and clear the accumulated timer.
8. The method for protecting new wire in wire EDM based on cumulative timing of processing status as described in claim 7, characterized in that, In step 9, if the machine tool is detected to be currently in the machining execution state when the forced return operation is terminated immediately, the parameter reload mechanism is immediately triggered to restore the current machining parameters to the latest non-protection setting value before entering the forced protection state.