Liquid level control device of low-speed wire cutting machine tool

Abstract

The embodiment of the utility model provides a liquid level control device of a low-speed wire cutting machine tool, which comprises a liquid level pressure sensor arranged in a working liquid tank of the low-speed wire cutting machine tool; the digital analog converter is connected with the liquid level pressure sensor; the signal acquirer is connected with the low-speed wire cutting machine tool; the first comparator is connected with the digital-to-analog converter and the signal acquirer; the motor controller is connected with the first comparator; the driver is connected with the motor controller; signals of the pressure sensor and the motor in the novel structure are converted into encoder signals and upper and lower limit switch signals required by an original machine tool system, and the water level of the working liquid tank of the machine tool is efficiently and reliably adjusted under the condition that original control software and a control circuit of the machine tool are not changed. The machining precision and stability of a machine tool are effectively improved, and the strict requirement of industrial production for liquid level control is met.

Description

Technical Field

[0001] The present application relates to the field of machine tool control, and in particular to a liquid level control device for a wire-cutting machine tool. Background Art

[0002] During the machining process, the height of the liquid level directly affects the stability and accuracy of the machining process, so accurate control of the liquid level is crucial. Traditional machine tool liquid level control systems mainly use two methods: overflow control or bottom liquid level control.

[0003] Overflow control systems typically use an overflow float and a pull rod to adjust the liquid level. When the liquid level rises to a set height, the float rises and triggers a control mechanism to begin discharging liquid to maintain a stable level. This approach offers the advantages of a relatively simple design and reliable structure. However, the system is susceptible to float drift and external interference. Because it relies on the physical position of the float, level measurement is prone to deviations when the float drifts. Furthermore, the float is sensitive to external environmental interference (such as vibration and temperature changes), which can lead to inaccurate level control and, in turn, affect production stability.

[0004] In contrast, the downflow level control system detects liquid level changes through a level sensor and uses a motor to adjust the opening of the drain port. When the liquid level reaches the set value, the motor controls the drain port opening to maintain the liquid level within a reasonable range. Compared to the overflow control system, this approach is more responsive to the liquid level and enables more precise level regulation. However, while achieving precise control, this system also increases system complexity. The accuracy of controlling the drain port opening is crucial; improper control can result in over- or under-discharge. Furthermore, the accuracy and reliability of the level sensor significantly impact the overall effectiveness of the system. If the sensor is inaccurate or malfunctions, the accuracy and stability of the level control may be significantly compromised. Utility Model Content

[0005] In response to the problems in the prior art, the present application provides a liquid level control device for a wire-cutting machine tool, which can improve the stability and reliability of the liquid level control system and meet the requirements of industrial production for liquid level control accuracy and stability.

[0006] To solve the above technical problems, this application provides the following technical solutions:

[0007] The present application provides a liquid level control device for a wire-cutting machine tool, comprising:

[0008] A liquid level pressure sensor for collecting liquid level status is installed in the working liquid tank of the wire cutting machine tool;

[0009] A digital-to-analog converter for performing digital-to-analog conversion on the liquid level state to obtain a current liquid level signal, connected to the liquid level pressure sensor;

[0010] A signal capturer for collecting target liquid level signals corresponding to the uplink and downlink signals of the machine tool motor, connected to the wire-cutting machine tool;

[0011] a first comparator for comparing the current liquid level signal with the target liquid level signal, connected to the digital-to-analog converter and the signal capturer;

[0012] a motor controller for outputting a liquid level control signal according to a comparison result of the first comparator, connected to the first comparator;

[0013] A driver for controlling the motor according to the liquid level control signal and the motor limit state, connected to the motor controller;

[0014] A motor for controlling the rotational speed according to a driving instruction of a driver is connected to the driver.

[0015] According to any embodiment of the present application, the device further includes a counter for accumulating the uplink signal and the downlink signal of the machine tool motor, which is connected to the signal capturer and the comparator.

[0016] According to any embodiment of the present application, it also includes a code converter connecting the counter and the wire cutting machine.

[0017] According to any embodiment of the present application, it further includes a second comparator for comparing the target liquid level signal with a preset liquid level parameter, which is connected to the counter and the wire cutting machine.

[0018] According to any embodiment of the present application, it further includes a parameter setting terminal connected to the second comparator.

[0019] According to any embodiment of the present application, it also includes a timer for controlling the signal capturer to collect the uplink signal and the downlink signal of the machine tool motor according to a predetermined time interval, and is connected to the signal capturer.

[0020] According to any embodiment of the present application, the device further includes an adjustment controller for converting the comparison result of the first comparator into a corresponding control signal, and the adjustment controller is connected to the first comparator and the motor controller.

[0021] According to any embodiment of the present application, the driver is further configured to send a current motor limit signal to the motor controller.

[0022] According to any embodiment of the present application, the motor is further configured to send a current motor operating status to the motor control.

[0023] As can be seen from the above technical solution, this application provides a liquid level control device for a wire-cut EDM machine tool. This device converts the pressure sensor and motor signals in a new structure into the encoder signals and upper and lower limit switch signals required by the original machine tool system. This allows for efficient and reliable adjustment of the water level in the machine tool's working fluid tank without changing the machine tool's original control software and control circuits. The system provided by this application can reduce software development work, effectively improve the accuracy and stability of machine tool processing, and meet the stringent requirements of industrial production for liquid level control. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0025] Figure 1 This is a schematic structural diagram of the liquid level control device of the wire-cutting machine tool described in this application. DETAILED DESCRIPTION

[0026] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.

[0027] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0028] In this application, terms such as "upper," "lower," "left," "right," "front," "back," "top," "bottom," "inner," "outer," "center," "vertical," "horizontal," "transverse," and "longitudinal" indicate positions or locations based on the positions or locations shown in the accompanying drawings. These terms are primarily intended to better describe this application and its embodiments and are not intended to limit the devices, elements, or components indicated to having a specific orientation, or to being constructed or operated in a specific orientation.

[0029] Furthermore, some of the above terms may be used to express other meanings besides indicating a position or location. For example, the term "on" may also be used to indicate a dependency or connection in certain circumstances. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0030] Furthermore, the terms "installed," "disposed," "provided with," "connected," "connected," and "socketed" should be interpreted broadly. For example, they can refer to fixed connections, removable connections, or integral structures; mechanical connections or electrical connections; direct connections, indirect connections through an intermediary, or internal communication between two devices, elements, or components. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0031] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0032] Considering that the liquid level control systems in the prior art are either limited by the drift of the float and the influence of external interference on the accuracy, or rely on the liquid level sensor and the complicated precision control of the opening of the drain port, it is difficult to achieve high precision and high stability at the same time, the present application provides an embodiment of the liquid level control device of the wire cutting machine tool, see Figure 1 In this embodiment, the liquid level control device of the slow-moving wire cutting machine tool specifically includes a liquid level pressure sensor, which is arranged in the working liquid tank of the slow-moving wire cutting machine tool and is used to collect the liquid level status;

[0033] a digital-to-analog converter, connected to the liquid level pressure sensor, for converting the liquid level state into a current liquid level signal compatible with a machine tool control system;

[0034] A signal capture device is connected to the wire-cutting machine tool, and is used to collect the uplink signal and the downlink signal of the machine tool motor and convert them into a target liquid level signal;

[0035] a first comparator, connected to the digital-to-analog converter and the signal capturer, and configured to compare the current liquid level signal with the target liquid level signal;

[0036] a motor controller, connected to the first comparator, and configured to output a liquid level control signal according to a comparison result of the first comparator;

[0037] A driver, connected to the motor controller, for controlling the motor according to the liquid level control signal and the motor limit state;

[0038] The motor is connected to the driver and is used to control the speed according to the driving instruction of the driver until the current liquid level is equal to the target liquid level.

[0039] In an application, for example, when a liquid level pressure sensor detects the liquid level, the signal is processed by a digital-to-analog converter and converted into the current liquid level signal. Simultaneously, a signal capture device generates a target liquid level signal based on the up or down signal from the motor. A comparator compares the current liquid level with the target level. If the levels are not equal, the motor driver adjusts its speed according to the motor controller's instructions until the liquid level reaches the target height.

[0040] This application uses a high-precision liquid level pressure sensor as the core acquisition component to monitor the liquid level changes in the machine tool tank in real time. The liquid level pressure sensor can keenly sense the pressure exerted by the liquid and convert it into an electrical signal to reflect the change in the liquid level. Compared with traditional mechanical floats, the liquid level pressure sensor not only has higher accuracy and stability, but also can avoid the inaccuracy problems caused by float drift and external interference. The high-precision real-time monitoring mechanism ensures that the system can respond to subtle changes in the liquid level in a timely manner, providing an accurate data basis for subsequent signal processing.

[0041] For example, see Figure 1 After the liquid level control component collects the liquid level signal, the conversion component uses a high-performance digital signal processor (DSP) to fine-tune and convert the collected signal, thereby ensuring that the liquid level change can be quickly converted into a control signal that the system can understand. This not only ensures the accuracy of the signal, but also improves the response speed of the system under different liquid level conditions.

[0042] The control circuit, the core of the entire system, is designed to account for real-time changes in the liquid level and the dynamic response characteristics of the control system. Based on the difference between the current liquid level and the target level, the control circuit accurately generates adjustment signals, which in turn regulate the motor's motion via the motor controller and driver. To ensure liquid level stability, each variable (including the rate of liquid level change and the difference from the target level) is controlled to ensure that the system responds quickly and accurately, effectively avoiding overshoot or undershoot of the liquid level and ensuring that the liquid level remains within the preset range, providing a strong guarantee for the stable operation of the machine tool.

[0043] As can be seen from the foregoing description, the liquid level control device for a wire-cut EDM machine tool provided in the embodiments of this application converts the pressure sensor and motor signals in the new structure into the encoder signals and upper and lower limit switch signals required by the original machine tool system, achieving efficient and reliable adjustment of the water level in the machine tool's working fluid tank without changing the original control software and control circuits of the machine tool. The system provided by this application can reduce software development work, effectively improve the accuracy and stability of machine tool processing, and meet the strict requirements of industrial production for liquid level control.

[0044] As a preferred embodiment, Figure 1 As shown, a counter is also included, which is connected to the signal capturer and the comparator and is used to accumulate the uplink signal and the downlink signal of the machine tool motor to obtain the target liquid level signal.

[0045] The signal capturer monitors the machine tool's motor's motion and captures each upward and downward movement of the motor. These signals represent the direction and magnitude of the change in the liquid level caused by the motor's movement. Each time the motor moves upward, the liquid level rises; conversely, each time the motor moves downward, the liquid level falls. The counter accumulates these upward and downward movement signals to determine the target height the liquid level should reach at that moment.

[0046] In one embodiment, the counter is implemented using digital logic, typically including incrementing and decrementing functions. When the motor's uplink signal is transmitted to the counter, the counter value increments by a predetermined amount. Conversely, when the downlink signal is transmitted, the counter value decrements. This accumulation and decrementing process allows the counter to track changes in the liquid level and calculate the expected liquid level based on the accumulated motor movement.

[0047] As a preferred embodiment, Figure 1 As shown, it also includes a code converter connected to the counter and the wire-cutting machine tool, which is used to convert the target liquid level signal into an analog liquid level signal compatible with the machine tool control system and input it into the wire-cutting machine tool.

[0048] After the counter accumulates the motor's up and down signals, it calculates the current target liquid level. This signal is usually in digital form. To ensure that this digital signal is compatible with the machine tool's control system, especially some more traditional or older machine tool systems, an encoder converter needs to convert the digital signal into a corresponding analog signal, such as a voltage or current signal. The control architecture of many traditional machine tool systems relies on analog signal input. Therefore, this conversion process makes the system compatible with different machine tools, whether modern digital control systems or traditional analog control systems, and can accept signals from the liquid level control system.

[0049] As a preferred embodiment, Figure 1 As shown, a second comparator is also included, which is connected to the counter and the wire-cutting machine tool and is used to compare the target liquid level signal with the preset liquid level parameter to obtain the upper limit and lower limit of the liquid level.

[0050] The second comparator compares the target level signal generated by the counter with the preset level parameters to determine the upper and lower limits of the liquid level. This comparison process ensures that the liquid level remains within the preset safety range, preventing it from being too high or too low, which could affect the stability of the process.

[0051] As a preferred embodiment, Figure 1 As shown, it also includes a parameter setting terminal connected to the second comparator for receiving the liquid level parameter input by the user.

[0052] Preset liquid level parameters, including upper and lower liquid level limits, can be input through the control system or user interface. A second comparator receives the target liquid level signal from the counter and compares it with these preset values, enabling the system to monitor the liquid level in real time and maintain it within a set safety range.

[0053] As a preferred embodiment, Figure 1 As shown, a timer is also included, which is connected to the signal capturer and is used to control the signal capturer to collect the uplink signal and the downlink signal of the machine tool motor according to a predetermined time interval.

[0054] The timer controls the signal capturer, allowing it to collect the machine tool motor's uplink and downlink signals at preset intervals. This timer ensures that the signal capturer regularly and stably obtains information about the motor's motion status, avoiding inaccurate data or system overload caused by overly frequent or infrequent sampling.

[0055] As a preferred embodiment, Figure 1As shown, an adjustment controller is also included, which is connected to the first comparator and the motor controller and is used to convert the comparison result of the first comparator into a corresponding control signal.

[0056] The adjustment controller converts the output of the first comparator into a control signal for controlling the motor. When the first comparator compares the current liquid level signal with the target liquid level signal, the adjustment controller generates a corresponding signal based on the comparison result, instructing the motor to move upward, downward, or maintain its current state, thereby achieving precise adjustment of the liquid level.

[0057] For example, the adjustment controller is responsible for converting the comparison result of the first comparator into an appropriate control signal and adjusting the operation of the motor through the PID controller. The adjustment controller first receives the output signal of the first comparator and monitors the feedback from the motor controller, such as the speed and position of the motor. Based on these input signals, the adjustment controller dynamically adjusts the motor through the PID controller. The proportional, integral, and differential parts in the PID controller can optimize the movement of the motor and ensure that the liquid level adjustment is both fast and stable. Before the input signal enters the PID controller, the high-frequency noise is eliminated by the filtering circuit to ensure the stability of the signal. The output signal of the adjustment controller is amplified and transmitted to the motor controller. At the same time, the limiter circuit prevents the signal from being too large, causing the motor to overspeed or system instability. Through this design, the coordinated work of the adjustment controller and the motor controller can ensure that the system makes stable liquid level adjustments according to liquid level changes.

[0058] It is understandable that dynamic adjustment of the motor based on the PID controller is a currently existing control design method, which will not be described in detail in this novel invention.

[0059] Furthermore, the main function of the motor controller is to adjust the motion state of the motor according to the output signal of the first comparator. Its structure includes a signal input part, a control circuit and an output part. The motor controller receives the liquid level difference signal from the first comparator and amplifies the signal through an internal signal amplifier to generate sufficient voltage or current to drive the motor. Through the built-in PWM (pulse width modulation) generator, the motor controller can control the speed of the motor. The signal is transmitted to the motor through the power amplifier to ensure that the motor runs at the expected speed and direction. In addition, the motor controller also includes a feedback loop to monitor the actual operating status of the motor, such as speed and position, and transmits feedback information to the adjustment controller to ensure that the motor accurately executes the adjustment instructions.

[0060] As a preferred embodiment, Figure 1As shown, the adjustment controller is used to output a liquid level control signal for increasing the motor speed when the current liquid level is less than the target liquid level, and to output a liquid level control signal for reducing the motor speed when the current liquid level is greater than the target liquid level.

[0061] Specifically, if the current liquid level is below the target level, the adjustment controller generates a control signal to increase the motor speed or raise the motor position. If the current liquid level is above the target level, it generates a signal to reduce the motor speed or lower the motor. These control signals are then transmitted to the motor controller, instructing the motor to perform the corresponding actions. Through this mechanism, the adjustment controller ensures that the liquid level is precisely adjusted to the target range, ensuring efficient and stable system operation.

[0062] As a preferred embodiment, Figure 1 As shown, the driver is also used to send the current motor limit signal to the motor controller.

[0063] The driver monitors the motor's travel position in real time. When the motor reaches a preset limit, the limit sensor is triggered. Upon receiving this signal, the driver immediately generates a limit signal and transmits it to the motor controller. Upon receiving the limit signal, the motor controller halts further motion instructions to ensure the motor does not exceed its physical limits, protecting the machine tool's safety and the system's normal operation. This limit protection mechanism effectively prevents accidental overloads or mechanical damage.

[0064] As a preferred embodiment, Figure 1 As shown, the motor is also used to send the current motor operating status to the motor control.

[0065] For example, the motor is equipped with a position sensor, speed sensor, or other detection device. When the motor is running, its state parameters are transmitted to the motor controller via a signal transmission line. The motor controller adjusts the control strategy based on the real-time motor state to ensure that the motor's operation matches the target liquid level. This real-time state feedback mechanism helps improve the system's response speed and control accuracy, and ensures that the motor always operates within a safe operating range.

[0066] The above description is only an illustrative embodiment of the present invention and is not intended to limit the scope of the present invention. Any equivalent changes and modifications made by those skilled in the art without departing from the concept and principle of the present invention shall fall within the scope of protection of the present invention.

Claims

1. A liquid level control device for a wire cutting machine tool, characterized in that: include: A liquid level pressure sensor for collecting liquid level status is installed in the working liquid tank of the wire cutting machine tool; A digital-to-analog converter for performing digital-to-analog conversion on the liquid level state to obtain a current liquid level signal, connected to the liquid level pressure sensor; A signal capturer for collecting target liquid level signals corresponding to the uplink and downlink signals of the machine tool motor, connected to the wire-cutting machine tool; a first comparator for comparing the current liquid level signal with the target liquid level signal, connected to the digital-to-analog converter and the signal capturer; a motor controller for outputting a liquid level control signal according to a comparison result of the first comparator, connected to the first comparator; A driver for controlling the motor according to the liquid level control signal and the motor limit state, connected to the motor controller; A motor for controlling the rotational speed according to a driving instruction of a driver is connected to the driver.

2. The liquid level control device for a wire-cutting machine tool according to claim 1, characterized in that: It also includes a counter for accumulating the uplink signal and the downlink signal of the machine tool motor, which is connected to the signal capturer and the comparator.

3. The liquid level control device for a wire-cutting machine tool according to claim 2, characterized in that: It also includes a code converter, which connects the counter and the wire cutting machine.

4. The liquid level control device for a wire-cutting machine tool according to claim 2, characterized in that: It also includes a second comparator for comparing the target liquid level signal with a preset liquid level parameter, which is connected to the counter and the wire cutting machine.

5. The liquid level control device for a wire-cutting machine tool according to claim 4, characterized in that: It also includes a parameter setting terminal connected to the second comparator.

6. The liquid level control device for a wire-cutting machine tool according to claim 1, characterized in that: It also includes a timer for controlling the signal capturer to collect the uplink signal and the downlink signal of the machine tool motor according to a predetermined time interval, and is connected to the signal capturer.

7. The liquid level control device for a wire-cutting machine tool according to claim 1, characterized in that: It also includes an adjustment controller for converting the comparison result of the first comparator into a corresponding control signal, and is connected to the first comparator and the motor controller.

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