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Several introductions of troubleshooting methods of wire electric discharge machine

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Several introductions of troubleshooting methods of wire electric discharge machine

来源: http://fxhhsgs.com点击: Date: 2016-05-11 11 : 05Source : http : //fxhhsgs.comClick :

1. Routine inspection method Routine inspection method refers to the routine inspection performed by maintenance personnel before the equipment is started. It includes the following aspects:
(1) Power supply
Check the power supply of the wire electric discharge machine, whether its voltage fluctuation is within the range of ± 10%, whether the high-order harmonics are serious, the size of the power factor, whether a regulated power supply is required and so on.
(2) Wire-cutting processing fluid The function of wire-cutting processing fluid is cooling, washing, chip removal, etc. Therefore, whether the wire-cutting processing fluid is qualified is directly related to the quality of the workpiece after processing. Check whether the wire-cutting processing fluid is too dark and has an abnormal odor. If so, its overall performance will be poor, and it will easily cause wire breakage.
(3) electrode wire (molybdenum wire)
The quality of the electrode wire, installation, and storage are directly related to the quality of the workpiece after processing. Check whether the electrode wire is selected properly. Use thicker electrode wire for processing thick workpieces, which is conducive to chip removal and increase its tension. Check the tightness of the electrode wire installation. When it is too loose, the electrode wire shakes violently and breaks the wire easily. Is too tight, the internal stress increases, and the wire is easy to break; check whether the position of the electrode wire installation is off-center from the same plane, if it is, the electrode wire is easily caught or pinched; check whether the wire is stored Standards, such as moisture, oxidation, exposure during storage, then the electrode wire will become brittle and easily broken.
(4) Control cabinet
Due to static electricity and other reasons, the control cabinet is easily dusty. When this dust is wet, it will corrode the circuit board, cause short circuit or open circuit, and then damage electronic components, etc., and even the entire circuit board is scrapped. Therefore, it must be checked before repair.
Example 1: A wire cutter breaks wires randomly at regular intervals. Sometimes it can run continuously for a day, sometimes it breaks several times a day. The inspection revealed that the wire-cutting processing solution was black, but there was no odor. After careful observation, it is found that there are too many impurities in the wire cutting processing fluid, which results in poor insulation and eventually causes irregular wire breaks. After replacing the new processing fluid, the fault is removed.
Consumable inspection method
The wearing parts inspection refers to the parts to be inspected by the maintenance personnel for the faults that occur after the equipment is started. After the equipment runs for a long time, most of the failures are caused by the damage of the wearing parts. The wearing parts mainly include a guide wheel, a wire blocking device, a wire breaking protection wire blocking body, a conductive block, a cushion pad, and a stroke switch. The following briefly introduces how maintenance personnel perform inspections of wearing parts.
(1) Guide wheel
The main role of the guide wheel is to reduce friction and position the molybdenum wire. If there are problems such as the incorrect position of the guide wheel, the non-rotation of the guide wheel, and the groove on the surface of the guide wheel, a variety of difficult problems will be caused. The position of the guide wheel is not correct, and it is impossible to produce a qualified workpiece; if the guide wheel does not rotate, the surface wear increases, and the surface of the guide wheel will be cut into a groove by the molybdenum wire soon. If the groove is shallow, when the molybdenum wire has a large jitter, it will cause the molybdenum wire to be too close to the workpiece, which will cause the discharge current to be too large or the molybdenum wire to be burned due to the arc, and the surface quality of the cutting surface will be poor; The groove is deep, and the molybdenum wire moving at high speed will be pinched by the two walls of the groove under a slight jitter. Therefore, maintenance personnel must carefully check the surface of the guide wheel that is in contact with the molybdenum wire.
(2) Wire blocking device
The main function of the wire blocking device is to locate the molybdenum wire. When checking, be sure to pay attention to whether the wire column in the wire blocking device is close to the molybdenum wire, and whether the wire column has been cut into a groove. In addition, it is necessary to carefully observe whether there is any overlapped wire on the wire storage cylinder.
(3) Broken wire protection wire body
The main role of the wire break protection wire body is wire break protection to prevent the electrode wire from being disturbed due to wire break. During the inspection, measure whether the wire-break protection switch is normally closed. If not, adjust the position of the wire-break protection block body so that the wire-break protection switch is normally closed.
(4) Conductive block
The main function of the conductive block is to conduct electricity. The conductive block is easily damaged, such as being cut into deep grooves, and the surface is oxidized. This will cause the conductive block to have poor contact with the molybdenum wire. When the contact is poor, the high-frequency pulse current may be small, or even no high-frequency pulse current is output.
(5) cushion
The cushion pad acts as a cushion during commutation. During the inspection, listen to the sound of the wire walking mechanism, especially the sound of the commutation. If the sound is abnormal, the accompanying vibration is very large. Generally, the cushion is damaged.
(6) Position switch
The main function of the limit switch is to commutate or cut off the high frequency.
The wire transport motor cannot be commutated; the commutation cannot break the high frequency. After frequent pressing, the position switch is easily damaged or has poor contact. When the trip switch fails, the contactor cannot be powered off, which causes the wire transport motor to be unable to reverse. Some wire cutters use another pair of contacts of the travel switch as a control signal for breaking high frequency. When the travel switch has poor contact or is damaged, the commutation cannot break high frequency.
Example 2: A wire cutting machine is constantly reversing high frequency. The inspection found that the broken wire protection block body had been cut into deep grooves. Since the broken wire protection control circuit did not have the function of controlling the main power supply, it only controlled the high frequency circuit. Therefore, when the wire blocking body is cut into a deep groove, the micro switch is changed from a normally closed state to a normally open state due to the sagging of the iron block, so that the high frequency circuit cannot be closed. Replace the wire block, and the fault is eliminated.
3. Principle Analysis
The principle analysis method refers to the detailed understanding of the fault, according to the working principle of the EDM machine, analyze the cause of the fault, and find a solution to the problem as much as possible. There are many such methods, the most commonly used are the following:
(1) Rounded to zero
The principle diagram is divided into main circuit and control circuit according to different functions. The main circuit mainly includes the wire transport motor and water pump motor circuit. The control circuit mainly includes a trigger circuit, an adjustment circuit, a drive circuit, and a single board computer control circuit. When a fault occurs, according to the analysis of the fault phenomenon, which part should the fault belong to, so that the scope of the fault is gradually reduced, and the fault can be quickly eliminated.
(2) Reverse analysis
When it is basically determined that a certain small area has a fault, a reverse analysis method can be used. That is to say what kind of situation will occur when the circuit is not open or the circuit is shorted somewhere, theoretically simulate the state that should be displayed when a fault occurs, so as to determine the cause of the fault.
(3) Circuit simulation
When a major fault occurs in an electronic circuit, it is common practice to use an oscilloscope to check the output signals of important links, such as voltage and waveform, to determine whether the component is damaged. However, it is often impossible to determine whether the output signal is correct after a simple measurement, so using electronic circuit simulation software is the best choice. Circuit simulation can help us determine more quickly whether electronic circuit components are damaged.
(4) Replacement of spare parts
For various reasons, it is often difficult for maintenance personnel to obtain a complete electronic circuit diagram. When a major fault occurs, only the approximate cause of the fault can be analyzed. Maintenance personnel can use spare printed circuit boards, vulnerable electronic components, etc. to replace the equipment, so that the equipment can be put into operation as soon as possible.
Example 3: A wire cutting machine increases the frequency doubling, the high frequency current display does not change, and the speed of wire cutting processing is very slow. It can be known from the rounding to zero that there is a problem with the adjustment circuit. Open the control cabinet and check that the contact point of the input signal of the frequency doubling circuit has been virtual connected. No matter what position it is adjusted to, the output voltage is always zero. After re-soldering, the fault is eliminated.
1. Routine inspection method Routine inspection method refers to the routine inspection performed by maintenance personnel before the equipment is started. It includes the following aspects:
(1) Power supply
Check the power supply of the wire electric discharge machine, whether its voltage fluctuation is within the range of ± 10%, whether the high-order harmonics are serious, the size of the power factor, whether a regulated power supply is required and so on.
(2) Wire-cutting processing fluid The function of wire-cutting processing fluid is cooling, washing, chip removal, etc. Therefore, whether the wire-cutting processing fluid is qualified is directly related to the quality of the processed workpiece. Check whether the wire-cutting processing fluid is too dark and has an abnormal odor. If so, its overall performance will be poor, and it will easily cause wire breakage.
(3) electrode wire (molybdenum wire)
The quality of the electrode wire, installation, and storage are directly related to the quality of the workpiece after processing. Check whether the electrode wire is selected properly. Use thicker electrode wire for processing thick workpieces, which is conducive to chip removal and increase its tension. Check the tightness of the electrode wire installation. When it is too loose, the electrode wire shakes violently and breaks the wire easily Is too tight, the internal stress increases, and the wire is easy to break; check whether the position of the electrode wire installation is off-center from the same plane, if it is, the electrode wire is easily caught or pinched; check whether the electrode wire is stored Standards, such as moisture, oxidation, exposure during storage, then the electrode wire will become brittle and easily broken.
(4) Control cabinet
Due to static electricity and other reasons, the control cabinet is easily dusty. When this dust is wet, it will corrode the circuit board, cause short circuit or open circuit, and then damage electronic components, etc., and even the entire circuit board is scrapped. Therefore, it must be checked before repair.
Example 1: A wire cutter breaks wires randomly at regular intervals. Sometimes it can run continuously for a day, sometimes it breaks several times a day. The inspection revealed that the wire-cutting processing solution was black, but there was no odor. After careful observation, it is found that there are too many impurities in the wire cutting processing fluid, which results in poor insulation and eventually causes irregular wire breaks. After replacing the new processing fluid, the fault is removed.
Consumable inspection method
The wearing parts inspection refers to the parts to be inspected by the maintenance personnel for the faults that occur after the equipment is started. After the equipment runs for a long time, most of the failures are caused by the damage of the wearing parts. The wearing parts mainly include a guide wheel, a wire blocking device, a wire breaking protection wire blocking body, a conductive block, a cushion pad, and a stroke switch. The following briefly introduces how maintenance personnel perform inspections of wearing parts.
(1) Guide wheel
The main role of the guide wheel is to reduce friction and position the molybdenum wire. If there are problems such as the incorrect position of the guide wheel, the non-rotation of the guide wheel, and the groove on the surface of the guide wheel, a variety of difficult problems will be caused. The position of the guide wheel is not correct, and it is impossible to produce a qualified workpiece; if the guide wheel does not rotate, the surface wear increases, and the surface of the guide wheel will be cut into a groove by the molybdenum wire soon. If the groove is shallow, when the molybdenum wire has a large jitter, it will cause the molybdenum wire to be too close to the workpiece, which will cause the discharge current to be too large or the molybdenum wire to be burned due to the arc, and the surface quality of the cutting surface will be poor; The groove is deep, and the molybdenum wire moving at high speed will be pinched by the two walls of the groove under a slight jitter. Therefore, maintenance personnel must carefully check the surface of the guide wheel that is in contact with the molybdenum wire.
(2) Wire blocking device
The main function of the wire blocking device is to locate the molybdenum wire. When checking, be sure to pay attention to whether the wire column in the wire blocking device is close to the molybdenum wire, and whether the wire column has been cut into a groove. In addition, it is necessary to carefully observe whether there is any overlapped wire on the wire storage cylinder.
(3) Broken wire protection wire body
The main role of the wire break protection wire body is wire break protection to prevent the electrode wire from being disturbed due to wire break. During the inspection, measure whether the wire-break protection switch is normally closed. If not, adjust the position of the wire-break protection block body so that the wire-break protection switch is normally closed.
(4) Conductive block
The main function of the conductive block is to conduct electricity. The conductive block is easily damaged, such as being cut into deep grooves, and the surface is oxidized. This will cause the conductive block to have poor contact with the molybdenum wire. When the contact is poor, the high-frequency pulse current may be small, or even no high-frequency pulse current is output.
(5) cushion
The cushion pad acts as a cushion during commutation. During the inspection, listen to the sound of the wire walking mechanism, especially the sound of the commutation. If the sound is abnormal, the accompanying vibration is very large. Generally, the cushion is damaged.
(6) Position switch
The main function of the limit switch is to commutate or cut off the high frequency.
The wire transport motor cannot be commutated; the commutation cannot break the high frequency. After frequent pressing, the position switch is easily damaged or has poor contact. When the trip switch fails, the contactor cannot be powered off, which causes the wire transport motor to be unable to reverse. Some wire cutters use another pair of contacts of the travel switch as a control signal for breaking high frequency. When the travel switch has poor contact or is damaged, the commutation cannot break high frequency.
Example 2: A wire cutting machine is constantly reversing high frequency. The inspection found that the broken wire protection block body had been cut into deep grooves. Since the broken wire protection control circuit did not have the function of controlling the main power supply, it only controlled the high frequency circuit. Therefore, when the wire blocking body is cut into a deep groove, the micro switch is changed from a normally closed state to a normally open state due to the sagging of the iron block, so that the high frequency circuit cannot be closed. Replace the wire block, and the fault is eliminated.
3. Principle Analysis
The principle analysis method refers to the detailed understanding of the fault, according to the working principle of the EDM machine, analyze the cause of the fault, and find a solution to the problem as much as possible. There are many such methods, the most commonly used are the following:
(1) Rounded to zero
The principle diagram is divided into main circuit and control circuit according to different functions. The main circuit mainly includes the wire transport motor and water pump motor circuit. The control circuit mainly includes a trigger circuit, an adjustment circuit, a drive circuit, and a single board computer control circuit. When a fault occurs, according to the analysis of the fault phenomenon, which part should the fault belong to, so that the scope of the fault is gradually reduced, and the fault can be quickly eliminated.
(2) Reverse analysis
When it is basically determined that a certain small area has a fault, a reverse analysis method can be used. That is to say what kind of situation will occur when the circuit is not open or the circuit is shorted somewhere, theoretically simulate the state that should be displayed when a fault occurs, so as to determine the cause of the fault.
(3) Circuit simulation
When a major fault occurs in an electronic circuit, it is common practice to use an oscilloscope to check the output signals of important links, such as voltage and waveform, to determine whether the component is damaged. However, it is often impossible to determine whether the output signal is correct after a simple measurement, so using electronic circuit simulation software is the best choice. Circuit simulation can help us determine more quickly whether electronic circuit components are damaged.
(4) Replacement of spare parts
For various reasons, it is often difficult for maintenance personnel to obtain a complete electronic circuit diagram. When a major fault occurs, only the approximate cause of the fault can be analyzed. Maintenance personnel can use spare printed circuit boards, vulnerable electronic components, etc. to replace the equipment, so that the equipment can be put into operation as soon as possible.
Example 3: A wire cutting machine increases the frequency doubling, the high frequency current display does not change, and the speed of wire cutting processing is very slow. It can be known from the rounding to zero that there is a problem with the adjustment circuit. Open the control cabinet and check that the contact point of the input signal of the frequency doubling circuit has been virtual connected. No matter what position it is adjusted to, the output voltage is always zero. After re-soldering, the fault is eliminated.

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