中英文DK77系列数控电火花线切割机床使用说明书

1、封面：dk77 series nc edm wire-cutting machine tooldk77系列数控电火花线切割机床use description使用说明书ningbo zhongyuan machine tool co., ltd. 宁波中原机床有限公司catalogue目录machine tool use机床用途machine tool features机床特点main use主要用途structure and principle of operation工作原理及结构principle of operation工作原理mechanical system structure机械系

2、统结构technical parameters技术参数characteristic model stipulations特性型号的规定basic parameters基本参数machine tool handling and installation机床的搬运与安装machine tool handling and hoisting机床的搬运与吊装machine tool installation机床的安装machine tool adjustment and operation机床调整与操作preparation works准备工作coil holder adjustment线架调整work

3、table regulation工作台调整kinetic wire component adjustment and electrode wire coiling运丝部件调整及电极丝绕装guide wheel adjustment导轮的调整work-piece clamping工件装夹operation and points for attention操作及注意事项machine tool maintenance and trouble removal机床的维护与故障的排除machine tool maintenance机床的维护common troubles and removals of

4、the machine tool机床的常见故障与排除vulnerable part table易损零件表machine tool running system installation and use description机床电器安装及使用说明summary of machine tool running system and control system电器控制系统概述common troubles of machine tool running system: causes and removals电器常见故障：原因及排除safety protection measures of mac

5、hine tool running system机床电器安全保护措施schematic drawing of 25v drive head mains 25伏驱头电源原理图schematic drawing of machine tool running system机床电器原理图dk77 seriesdk77系列use description of machine tool机床使用说明书38 pages total共38页page 1第一页machine tool use机床用途machine tool features机床特点max. feature of this serial prod

6、uct lies in the fact that it has no special requirements to the processed metal material properties. in principle, it can process all the conductive materials such as super-hard and hard alloy, quenching materials, stainless steel ductile materials, various magnet steel fragile materials, uneasily-c

7、lamped thin wall spares etc. if the machine tool gets the aid of the auxiliary extra-large specification of “taper cutting device” and “responsive micro-computer system” produced by this company, then it can gain the satisfactory results in processing all kinds of the special spares which terrify ot

8、her machine tools. following the constant appearance of the high-tech products, it continuously prospers the national economy. we predict that the characteristics of this serial product will be further developed and utilized. it will find favor in the eyes of vast customers.本系列产品最大特点是对被加工的金属材料性质无特殊要

9、求，原则上凡导电材料均可加工。如超硬、硬质合金、淬火材料；如不锈钢类的韧性材料；各类磁钢的脆性材料；不易装夹的薄壁零件。若机床辅以本公司制造的特大规格锥度切割装置与响应微机系统，那么对其他机床望而生畏的各种特异零件加工都能取得令人满意的效果。随着高科技产品不断出现，国民经济的不断繁荣，我们预言，本系列产品的特点将进一步得到开发利用，受到各位客户的欢迎。main use主要用途it processes various molds such as rubber and plastic molds, punch die and so on.加工各类模具：橡塑模、冲模等等。it processes t

10、he special materials of fragile materials, stainless steel ductile materials, super-hard materials.加工特殊材料：脆性材料、不锈钢韧性材料、超硬材料。it processes the complex-shape spares such as the tapered upper and lower specially-shaped spares and so forth.加工复杂形状零件：带锥度的上下异形零件等。structure and principle of operation工作原理及结构p

11、rinciple of operation工作原理the serial product applies “electrical discharge machining” mechanism. it gets the auxiliary aid from electro-mechanically integrated product which combines automated control with micro-computers. the machine tool usually adopts “molybdenum wire” or “hard brass wire” as the

12、“tool electrode”. under the “high frequency pulse voltage functions”, it utilizes the effect that it forms “spark discharge” after the liquid medium has been broken down. it instantaneously produces great volumes of heat energy in the spark channel. it melts or even gasifies the metal in the surface

13、 of the work-piece. with the joint action of the liquid medium, the metal has been rapidly eroded and removed. the work-piece which has been chucked in the coordinates work-table has been processed into various required shapes according to the pre-formulated program under the micro-computer control.

14、本系列产品是应用“放电加工”机理，辅以自动控制及微机相结合的机电一体化产品。机床通常采用钼丝或硬性黄铜丝作为工具电极，在高频脉冲电压作用下，利用液体介质被击穿后形成火花放电，在火花通道中瞬间产生大量的热能，使工件表面的金属熔化甚至气化，加上液体介质的共同作用，而使金属被迅速蚀除下来。装夹于座标工作台上的工件在微机控制下按预行编制的程序被加工出各种所需的形状。please refer to diagram 1 for its basic composition其基本组成见图1file文件programming编程reader输入机power amplification功放micro-comput

15、er微机variable frequency变频detection检测calculation system运算系统step-motor步进电机machine tool机床pulse mains脉冲电源diagram 1图1machine tool composition diagram机床组成方框图page 2第二页we can see from the above diagram that the whole system is composed of the “computer system”, “machine tool control system”, “mechanical syst

16、em”. the processing documents” form “computer-input machine tool control system” through programming. the “control system” controls the “machine tool” to complete the program actions and therefore finishes the processing instructions. the “mechanical system” is based upon the “machine tool body”. it

17、 includes the “coordinates work-table”, “kinetic wire system”, “cooling system”.由上图可见整个系统主要由计算机系统、机床控制系统和机械系统组成。加工文件通过编程形成计算机输入机床控制系统，并由控制系统控制机床完成程序的动作，以此完成加工指令。机械系统以床身为基础，包括坐标工作台、运丝系统、冷却系统。the “micro-computer system” allocated by this machine tool is a new generation “control system”. for details,

18、please refer to “use description and machine tool running system parts”. it mainly consists of the micro-computer with the collocation of “special-purpose interpolating control software”, “interface circuit”, “stepping drive circuit”. it has the sound operationality because of the adoption of the ad

19、vanced cnc technology. 本机所配的微机系统是新一代的控制系统，详见使用说明书、电器部分。其主要由微机配上专用的插补控制软件及接口电路和步进驱动电路组成，由于采用了先进的cnc技术，所以具有良好的操作性。mechanical system structure机械系统结构the mechanical system part of this “machine tool” is composed of the key elements such as the “machine tool body”, “work-table”, “kinetic wire device”, “co

20、il holder” (including taper device), “cooling system” etc.本机床的机械系统部分由床身、工作台、运丝装置、线架（包括锥度装置）及冷却系统等重要部件组成。machine tool body床身“machine tool body” is a basic part of the “machine tool”. if all these components have been installed in the body, it can guarantee the high accuracy to the whole system becaus

21、e of the enough rigidity and vibration-resistance. there are two “hoisting screws” mounted respectively in the fore-and-aft sides of the “machine tools” below dk7750 which have been produced by this company. they function as hanging the “machine tool”. it can remove the “hoisting screws” after insta

22、llation. the large-size machine tools use the “hoisting holes”. the “supporting feet” with the adjustable level have been installed in the bottom of the “machine tool body”. 床身是机床的基础件。以上这些部件都装在其上，所以其足够的刚性与抗振性使整个系统有高精度的保证。本公司生产的dk7750以下机床，其床身前、后两面各装有两个起吊螺丝，其作用是吊装机床使用。起吊螺丝安装后可拆下，大型机床用起吊孔，床身底部装有可供调节水平的

23、支承脚。work-table工作台the worktable is composed of two “upper and lower tool carriages” making relative cross movements and precise “lead-screw drive pair”. please refer to table 2 and 3 for the “drive system”.工作台是由二块相对十字运动的上下拖板及精密丝杠传动副所组成，其传动系统见图2和图3。the structural formula of “v-thread drive” is as foll

24、ows: (see table 2)三角螺纹传动的结构式如下（见图2）x-directional: feed pulse step-motor e1 gear pair z1/z2 lead-screw m1x向：进给脉冲步进电机e1齿轮副z1/z2丝杠副m1y-directional: feed pulse step-motor e2 gear pair z3/z4 lead-screw pair m2y向：进给脉冲步进电机e2齿轮副z3/z4丝杠副m2the structural formula of ball-screw drive pair is as follows: see tab

25、le 3滚珠丝杠传动副的结构式如下，见图3：x-directional: feed pulse step-motor e1 gear pair z1/z2 lead-screw pair g1x向：进给脉冲步进电机e1齿轮副z1/z2丝杠副g1y-directional: feed pulse step-motor e2 gear pair z3/z4 lead-screw pair g2y向：进给脉冲步进电机e2齿轮副z3/z4丝杠副g2in addition, it can also fulfill the quick movement of the “work-table” throug

26、h “x-directional and y-directional handles”.另外通过x向、y向两个手柄，也可实现工作台快速移动。page 3第三页electrode wire电极丝kinetic wire tube运丝筒tacking紧钉guide screw b丝杆bwire-positioning wheel排丝轮handle手柄conductive wheel导电轮guide wheel导轮diagram 2图2v-thread drive system三角螺纹传动系统diagram 3图3ball-screw and synchronous belt drive syste

27、m滚珠丝杠及同步带传动系统page 4第四页kinetic wire device运丝装置it consists of the motor, coupler, “wire storage tube”, “gear drive components”, “slide plate”, “kinetic wire base”, “lead-screw pair” etc. because of the action of “left & right link stoppers” and “stroke switch”, it implements the reciprocating movement

28、s to the “electrode wire” that has been coiled in “wire storage tube” in order to complete cutting to “work-pieces”.由电机、联轴器、贮丝筒、齿轮传动部件、滑板、动丝底座及丝杠副等组成。由于左右撞块及行程开关的作用，使缠绕在贮丝筒的电极丝实现往复运动，来完成对工件的切割。please see diagram 2 or diagram 3 for the drive system:其传动系统见图2或图3：motor h coupler high speed rotating wire

29、 tube gear z5/z6z7/z8 lead-screw pair t电机h联轴器高速旋转丝筒齿轮z5/z6z7/z8丝杠副t。coil holder线架“coil holder” is a device which supports the “electrode wire”, adjusts the “cutting thickness” and carries out various “taper cutting”. it installs the “electrode wire” onto “work-piece” which has been chucked in the “w

30、ork-table” through “wire-positioning wheel”, “conductive device”, “guide-wheel group”. “conductive block” electrifies “electrode wire” under action of “hf pulse mains”. the “liquid medium” ejected from “liquid injection device” has been broken down to form “spark discharge” which completes the “work

31、-piece cutting”. 线架是用来支承电极丝，调节切割厚度及进行各种锥度切割的一个装置。它通过排丝轮，导电装置及导轮组，将电极丝引到装夹于工作台上的工件上。由于通过导电块在高频脉冲电源作用下，使电极丝带电，利用喷液装置喷出来的液体介质被击穿后形成火花放电来完成对工件的切割。because it acts to various “structural composition” of the “coil holder”, it is divided into “fixed coil holder”, “adjustable coil holder”, “taper coil holder

32、”.由于作用不同线架的结构形成，通常有固定线架，可调线架及锥度线架之区别。fixed coil holder固定线架the “upper and lower coil holders” of such structural “coil holder” have been fixed above the “upright column”. it can not be adjusted. it has the advantages of the fine rigidity and sound machining stability. but its max. shortcoming lies in

33、 the small cutting range which can not be regulated. therefore it has limitations for the product machining. at present, it has been gradually replaced by the “adjustable coil holders”. 此种结构线架其上下悬臂固定于立柱之上，不可调节。其优点是刚性较好，加工稳定性也较好，但其最大缺点是切割范围较小，且不能调节，因此产品加工有局限性。目前已逐步被可调形线架所代替。elevated adjustable coil h

34、older升降式可调线架the “upper coil holder” can move up and down along the “upright column” so that it can adapt to the spare machining with different thickness.是使上悬架可沿立柱上下移动，以此来适应不同厚度的零件加工。tapered type coil holder锥度式线架in fact, this structure is the “elevated type” plus one “taper cutting device”. the “tape

35、r device” produced by our company has the multiple specifications such as 6, 12, 15, 30, 60 etc. it can basically satisfy various requirements from vast consumers. with the collocation of the corresponding “control device”, it can easily fulfill “x, y, u and v four-shaft linkage”.这种结构实际上是升降式再加上一个锥度切

36、割装置，本公司生产的锥度装置有6、12、15、30、60等各种规格，基本上能满足用户的各种需要，配上相应的控制装置能很容易地实现x、y、u和v四轴联动。technical parameters技术参数characteristic model stipulations特性型号的规定at present, dk77 serial goods produced by our company is mainly divided into three kinds of model e, model f, model g according to different “power stroke” (spe

37、cification) and structural form of the coil holder. 我公司目前生产的dk77系列产品，主要是按其工作行程（规格）及其线架结构形式不同可分为e型、f型和g型三种。model e adjustable coil holder height, therefore it is called “adjustable coil holder”.e型线架高度可调节，称可调线架。model f the “coil holder height” can be regulated, it is also allocated with below 6 taper

38、cutting device. therefore it is called “adjustable small-taper coil holder”.f型线架高度可调节且配以6以下锥度切割装置，称可调小锥度线架。model g the “coil holder height” can be regulated. it is also allocated with our patent “large-taper cutting device” with the “tracking hydrojet”. it is called “large taper coil holder”. it com

39、monly has 30 or 60 upper limit specifications and so on.g型线架高度可调节且配以由公司专利的带跟踪喷液的大锥度切割装置。大锥度线架，常用的有上限为30或60等各种规格。the model composition and representative meaning are in line with standards jb/t7445 and 2-94.型号组成及代表意义依据标准jb/t7445、2-94。coil holder form线架形式principal parameter (work-table lateral stroke

40、1/10)主参数（工作台横向行程1/10）machine tool series机床系列national machine tool no.机床组别machine tool properties机床特性machine tool category机床类别page 5第5页technical parameters技术参数unit: mm单位：mmmodel型号parameter参数power stroke工作行程max. length of machining part加工件最大长度max. width of machining part加工件最大宽度machining part thickness

41、加工件厚度cutting taper切割锥度model ff型model gg型max. weight of machining part加工件最大重量work-piece surface roughness工件表面粗糙度max. material removal ratio最大材料去除率current range of electrode wire电极丝电流范围operating mains工作电源max. machining current最大加工电流control mode控制方式control accuracy控制精度total weight of machine tool机床总重量o

42、uter diameter size of machine tool机床外径尺寸open-loop, step-motor drive开环、步进电机驱动description:说明：the above “cutting taper” and “operating thickness” take 150mm as the “calculation height”.以上切割锥度、工作厚度以150mm为计算高度；surface roughness ra2.5m has been determined when “cutting speed” is 20mm2/min.表面粗度ra2.5m，是在切割速

43、度为20mm2/min.时测定的。page 6第6页machine tool handling and installation机床的搬运和安装machine tool handling and hoisting 机床的搬运和吊装machine tool handling can be hoisted or use the lift-truck. please refer to diagram 4 for outer packing box hoisting. if there is no packing box, please refer to diagram 5 with the util

44、ization of double ends of machine tool body and four hoisting screws for lift. please be noted that the hoisting screw should be tightly wrenched and the face tightly stuck to the body. otherwise it easily breaks the screw root and causes the unnecessary accidents. as for the large-size machine tool

45、 above dk7763, it should use the enough intensity hoisting bar. soft materials should be filled between the wire rope and machine tool contact so that it will not damage the outer appearance. un-smooth circumstances such as jolt, tilt, impact etc. should be avoided in the handling. 机床的搬运可用吊装，也可用铲车。当

46、有外包装箱吊运时可见图4，若无包装箱则可利用床身两端，四只起吊螺丝起吊，见图5。注意起吊螺丝必须拧紧，其端面必须紧贴床身，否则螺丝根部容易折断，造成不必要的事故。对于dk7763以上的大型机床，必须用具有足够强度的起吊棒。钢丝绳与机床接触处要填放软性物质，以免损伤外观。搬运中应避免颠簸、倾斜、撞击等不平稳现象。machine tool installation机床安装it should keep a clean, dust-free installation environment without vibrating source; corrosive gas and large wattag

47、e electrical equipment interference. it better controls 205 to the operating environment temperature. 安装环境应清洁，无粉尘、无振动源，无腐蚀气体，无大功率电气设备干扰。建议工作环境温度最好控制在205。as far as the “installation direction of the machine tool” is concerned, it is better for the operator to face the “natural light source”. after th

48、e initial placement of the machine tool, firstly remove the “locking blocks” on both ends of the “guide rail” and replace them with the machine backups, then wash the key “drive members” such as “lead-screw pair”, “guide rail”, “guide wheel” etc. by the clean kerosene and immediately coat with clean

49、 hj-30 lubricant in order to prevent from rusting. relying on the adjustable screws below the “machine tool body”, it should not exceed 0.04/1000 requirements for the lateral and longitudinal directions of the “level gauge” in the “work-table”. the machine tool should have the reliable connection wi

50、th the “protective ground system” for purpose of ensuring the safe use. 机床安装方向尽量使操作者面对自然光源。机床初步安放后，应拆去导轨两端锁紧块，换上随机带的挡块，然后用干净煤油清洗丝杠副、导轨、导轮等重要传动件，要立即擦上清洁的hj-30机油以防生锈。借助床身下面的调整螺钉，使水平仪在工作台纵横二个方向均不得超过0.04/1000的要求。机床应与保护接地装置可靠连接，以确保使用安全。diagram 4图4hoisting diagram of outer packing lifting box外包装吊箱吊运图page

51、7第7页machine tool adjustment and operation 机床调整与操作preparation works准备工作on-line联机please carefully read “use description of two parts of machinery & machine tool running system” before on-line in order to correctly connect the sockets with various plugs.联机前应仔细阅读机械与电器二部分使用说明书，使其各个插头与插座，得以正确的联接。start the

52、 “mains switch”, make no-load running of the machine tool, observe whether it has the normal working condition or not.启动电源开关，让机床空载运行，观察其工作状态是否正常。the contents include the following:内容有：the “control cabinet” should have more than ten minutes normal operation.控制柜必须正常工作十分钟以上；it should have the normal op

53、eration for various parts of the “motion pair” in the machine tool.机床各部分运动副工作正常；no error in “pulse mains” and “machine tool running system operation”脉冲电源与机床电器工作无失误；it should have sensitive action of various “stroke switch contacts”.各个行程开关触点动作灵敏；smooth flow of the “working solution” in various “inlet

54、 and outlet pipes” with normal pressure, the “working solution” should wrap “molybdenum wire”. 工作液各进出管畅通无阻，压力正常，工作液裹住钼丝。fill the lubricant according to the lubricating demands of the machine tool.按机床润滑要求注油；see diagram 6, diagram 7 and table 2.见图6、图7和表2please accord with table 2 stipulations for mach

55、ine tool lubrication with regular oil adding. because it is a high speed wire-traveling machine tool, therefore whether various systems have normal lubrication or not is vital to the cutting accuracy and roughness. the consumers should think high of this very point.机床润滑请按表2规定，定期加油，由于本机床为高速走丝，所以各系统的润滑是否正常，对其切割精度与粗糙度是至关重要，因此务必请用户重视。diagram 5图5machine tool main frame hoisting diagram机床主机吊运图page 8