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

2、械系统结构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

3、调整Worktable 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

4、Removals of 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

5、Measures of Machine Tool Running System 机床电器安全保护措施Schematic Drawing of 25V Drive Head Mains25 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. feat

6、ure of this serial product lies in the fact that it has no special requirementsto the processed metal material properties. In principle, it canprocess all the conductive materials such as super-hard and hard alloy, quenching materials, stainless steel ductile materials, various magnet steel fragile

7、materials, uneasily-clamped thin wall spares etc.If the Machine Tool gets theaid of the auxiliary extra-large specification of “ Taper Cutting Device ” and “ Responsive Micro-Computer System” produced by this Company, then it cangain the satisfactory results in processing all kinds of the special sp

8、ares which terrify other Machine Tools.Following the constant appearance of the high-techproducts, it continuously prospersthe national economy. We predict that thecharacteristics of this serial product will be further developed and utilized.It willfind favor in the eyes of vast customers. 本系列产品最大特点

9、是对被加工的金属材料性质无特殊要求，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

10、工各类模具：橡塑模、冲模等等。It processes the 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。upper and lowerIt processes the complex-shape spares such as the tapered 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

11、Principle of Operation 工作原理及结构Principle of Operation 工作原理The serial product applies “ Electrical Discharge gets the auxiliary aid from electro-mechanically combines Automated Control with Micro-Computers. adopts “ Molybdenum Wire” or “ Hard Brass WireUnder the “ High Frequency Pulse Voltage Function

12、sMachining ”integratedmechanism. Itproduct whichThe Machine Tool usually ” as the “ Tool Electrode ” , it utilizes the effect that itItItforms “ Spark Discharge ” after the liquid medium has been broken down. instantaneously produces great volumes of heat energy in the Spark Channel. melts or even g

13、asifies the metal in the surface of the Work-Piece.With the jointaction 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 programunde

14、r the Micro-Computer Control.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

15、编程Reader输入机Power Amplification功放Micro-Computer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 systemis composed of the“Computer S ystem ”,“

16、Machine Tool ControlSystem ”, “ Mechanical System ”TheProcessing 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

17、 System ” is based upon the “ Machine Tool Body ”. It 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-ComputerSystem ” allocatedgeneratio

18、n “ Control SystemFor details,by this Machineplease refer toTool is a newUse Descriptionand Machine Tool RunningSystem PartsIt mainly consists of theMicro-Computer with the collocation of“ Special-Purpose Interpolating ControlSoftware ”, “ Interface Circuit”, “ Stepping Drive Circuit”. It has the so

19、undoperationality because of the adoption of the advanced 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 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。其主要由微机CNC 技术，所以具有良好的操作性。Mechanical System Structure 机械系统结构The MechanicalSystem Part of thisMachine Tool ” is composed of the keyelements such as the “ Machine

20、Tool BodyWork-Table ”, “ KineticWireDevice ”, “Coil 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 c

21、an guarantee the high accuracy tothe whole system because of the enough rigidity and vibration-resistance.Thereare 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 “Machin

22、e Tool ” . It can remove the “ Hoisting Screws ” after installation. 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 D

23、K7750 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 节水平的支承脚。Upper and Lower Tool Carriages“ Lead-Screw Drive Pair” making Please refer toWork-Table 工作台The Worktable is composed of two relative cross movements and precise 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

24、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 follows: (See Table 2)三角螺纹传动的结构式如下(见图 2 )X-Directional:Feed Pulse t Step-MotorE1tGearPairZ1/Z 2tLead-ScrewM1X向：进给脉冲-乍步进电机E1 t齿轮副 Z1/Z 2|T丝杠副M1Y-Directional:Feed Pulse t Step-MotorE2tGearPairZ3/Z 4tLead-ScrewPair M 2Y向：进给脉冲T

25、步进电机E2T齿轮副 Z3/Z 4T丝杠副M2The Structural Formula of Ball-Screw Drive Pair is as follows:See Table 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 Zi/Z 2 Lead-ScrewPair G 1X向：进给脉冲t步进电机E1 t齿轮副Z1 /Z 2 t丝杠副G1Y-Directional:Feed Pulse t Step-Motor E2t Gear Pair Z3/Z 4t Lead-ScrewPair G

26、2Y向：进给脉冲t步进电机E2t齿轮副Z3/Z 4t丝杠副G2Work-Table ” throughIn addition, it can also fulfill the quick movement of the “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Condu

27、ctive 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 System 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 ” ,

28、 “ Lead-Screw Pair ” etc. Because of the action of“ Left & Right Link Stoppers” and “ Stroke Switch ” , itimplements the reciprocating movements to the“ Electrode Wire ” that has beencoiled 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

29、。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 t Coupler High Speed Rotating Wire TubeGear Z 5/Z 6 Z7/Z 8Lead-Screw Pair T电机H t联轴器t高速旋转丝筒t齿轮Z5/Z 6 Z7/Z 8t丝杠副T。Coil Holder线架Coil holder ” is a device which supports Cutting T

30、hickness ” and carries out various Electrode Wire ” onto “ Work-Piece ”the “ Electrode Wire ” , adjusts the“ Taper Cutting” . It installs thewhich has been chucked in theWork-Table ” throughWire-PositioningWheel ” , “ ConductiveDevice“Guide-Wheel under actionGroup ” .“Conductiveof “HF Pulse Mains ”“

31、Liquid Injection Device which completes the 线架是用来支承电极丝，Block ” electrifies “Electrode Wire ” The “Liquid Medium ” ejected from” has been broken down to form“ Spark DischargeWork-Piece Cutting” .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， 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

32、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 isdivided into “Fixed Coil Holder ”, “Adjustable Coil Holder ”, “ Taper Coil Holder ”.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 been fixed above theLower Coil Holders “ Upright

33、Columnof such structuralCoil holder ” haveIt can not be adjusted.It has theadvantagesof the fine Rigidityand sound MachiningStability.But its max.shortcominglies in the small cuttingrange whichcan not be regulated.Therefore it has limitations for the product machining.At present, it has beengraduall

34、y 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 Holder 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 wit

35、h 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 “ Taper Device ” produced by our company has the multiple specifications such as 6 ° , 12 ° , 15 ° , 30 ° , 60

36、76; 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

37、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 ”(Specification) and Structural Form of the Coil Hol

38、der.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 CoilHolder ” .E 型线架高度可调节，称可调线架。Model F The “ Coil Holder H eight ”can be regulated, it is also allocated with below 6 ° Taper Cutting Device. Therefore it

39、 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 allocatedwith our patent“ Large-Taper Cutting Device” with the “ Tracking Hydrojet”It is called“ Large Taper Coil Holder” . It commonly has 30°

40、; or 60 ° UpperLimit 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-Tabl

41、e Lateral Stroke 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： mmModelParameter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Ma

42、chining Part Thickness 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To

43、tal Weight of Machine Tool 机床总重量Outer 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“ CalculationHeight ”.以上切割锥度、工作厚度以 150mm 为计算高度；Surface Roughness Ra < 2.5m has been determined whe

44、n“ Cutting Speed ” is220mm /min.表面粗度Ra w 2.5m，是在切割速度为 20mm 2/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

45、packing box, please referto diagram 5 with the utilization of double ends of machine tool body and four hoisting screws for lift.Please be noted that the hoisting screw should be tightlywrenched and the face tightly stuck to the body.Otherwise it easily breaks thescrew root and causes the unnecessar

46、y accidents.As for the large-size machinetool 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

47、 avoided in the handling.机床的搬运可用吊装，也可用铲车。当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 witho

48、ut vibrating source; corrosive gas and large wattage electrical equipment interference. It better controls 20± 5 °C 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 20±5C。As far as the“ Installation Directionof theMachine Tool ” isconcerned,it

49、isbetter for theoperator to face the“ NaturalLight Source ”.After theinitialplacement of the Machine Tool, firstly remove the “ Locking Blocks ” on both ends of the “ Guide Rail ” and replace them with the Machine Backups,thenwash the key“Drive Members ” such as “Lead-Screw Pair ”,“Guide Rail ”,“Gui

50、de Wheel ” etc. by the cleankeroseneand immediatelycoat withcleanHJ-30 Lubricant in order to prevent from rusting. Relying on the adjustable Screws below the “ Machine Tool Body ”, it shouldnot exceed 0.04/1000requirements for the lateral and longitudinal directions of the“Level Gauge ” inthe “Work-

51、Table ”. The Machine Tool should have the reliable connection with 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

52、保使用安全。Diagram 4图4Hoisting Diagram of Outer Packing Lifting Box外包装吊箱吊运图Page 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 ToolRunning System ” before on-line in order to correctly connect t

53、he 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 “ 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 h

54、ave 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 operation for various parts of the“ Motion Pair ” in theMachine 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

55、“ Stroke Switch Contacts” .各个行程开关触点动作灵敏；Smooth flow of the “Working Solution ” in various “ Inlet 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

56、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 Machine Tool Lubrication with regularoil adding. Because it is a high speed Wire-Traveling Machine Tool, therefore whether various systems have normal lubrication or not is vital tothe CuttingAccuracy 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