57974927 dk7740 d

CNC WIRE CUT EDM MACHINE

MANUAL

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1. Machine functions and applications Under the control of the CNC, the machine that depended on the electrode wire and high frequency supply cuts the workpiece according to the preparative scheduled track. The machine is designed by CAE. The structure is reasonable and the performance is predominant. Its rigidity is good, cutting force is low, movement is smooth, and manipulation is safe and reliable. The machine is fit for machining the metal molds of high precision, high hardness, high tenacity and complex-shape parts, especially stamping molds, die molds, plastic molds, roll gear tools and up-down differ-shape parts. The machine is a new production of WEDM. It is applied widely in the fields of machine industry, vehicle industry, aviation industry, home appliance, war industry, electron industry etc. And now it is a very important machine tool in manufacture fields. 2. Technical specifications 1. Working table travel mm × 2. Working table dimension mm × 3. Max. Machining thickness mm 4. Max. Taper angle (Thickness<100mm) 5. Mo. Wire diameter mm φ0.15~φ0.2 6. Max. Productivity ( Material: Cr12, Quench,40mm) >100mm2/min 7. The best surface rough μm

(Material: Cr12, Quench,40mm; once cutting& productivity=30 mm2/min) Ra≤2.5 (Material: Cr12, Quench,40mm; several times cutting& productivity=40 mm2/min) Ra≤1.2

8. Machining precise ( Material: Cr12, Quench, φ12×40mm) • Roundness (Below Dk7780 ≤0.015; Above Dk77100 ≤0.03) • Taper (6°WEDM ≤0.04; 30°, 60°WEDM ≤0.10)

9. Working table movement vector mm 10. Working table repeat position precision mm 11. Working table position precision Portrait mm Transverse mm 12. Max. workpiece weight Kg 13. Power Kw 2 14. Machine figure mm × × 15. Machine weight Kg 16. Power supply 3N-380V/50HZ 17. Machine noise Db ≤80dB

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3. Machine structure The machine is composed of the mechanism component, electric controller and coolant system. The mechanism component is consisted of machine body, working table, wire guide frame, taper cutting mechanism, wire traveling unit, working tank, fixture, water-repellent cover and coolant system etc. The linear roller guide ways and the super high precious ball screws are applied in the machine type below DK7750 (also including DK7750). One the other hand, the linear ball guide ways and the super high precious ball screws are applied in the machine type above DK7763. The span of the wire guide frame is adjustable to different type machine and the guide wheels are designed to double-support structure. ① The machine body The material of the cast is HT250, which makes the machine body has high load intensity and the ability to resist distortion. The vibration-resisted stow-irons are used in the connection of the machine body and groundwork. The installation and adjustment are convenience. The up saddle and the middle saddle are set on the top of the machine body, which are driven by X and Y ball screws. ② The wire traveling unit and the wire guide frame The to-and-fro rotation of the wire-winding drum drives the electrode wire reciprocating running. At the same time, the guide wheels and the wire let wheels keep the movement of the electrode wire smoothly. The top and bottom electrified blocks are used for electrifying, but if needed we also can use wire-winding drum to realize electrifying. ③ The taper cutting mechanism It’s driven by two step motors to realize U and V movement, which can make the machine accomplish 4 axis (X, Y, U, V) motion together. And according to the taper cutting mechanism, the machine can execute taper machining. ④ The working table There, the fixtures are fixed on the working table with T-shape slots i.e. the up saddle. ⑤ The coolant system The coolant system is composed of water tank, the working fluid, the flux valves, the pipe unit and the fine filter unit which can make the working fluid used repeatedly. The working fluid is very important to the machining, that is to say, it can affect the stability of machining and the surface quality of the machining workpiece. So you should change the working fluid after a period, when it’s dirty and ropy. When the pressure meter value is above 0.2Mpa, it suggest you should change the filter core. ⑥ The fixture and the spare part

• About the fixture: The pane fixtures are only for below type DK7750 WEDM and the shape fixtures are used on the others type WEDM.

• About the spare part: There is assembly and disassembly components, wire tighten components, bearing disassembly tools and the rotating handle in the spare part box.

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4. Driving system The driving system is consisted by the working table driving system, the wire traveling system and the taper driving system.

① The working table driving system (See to figure 4-1) X direction: The control system sends out a movement pulse → The step motor Q → The gears mate 23/24 → The ball screw 13 → The nut 14 drives the saddle to move. Y direction: The control system sends out a movement pulse → The step motor P → The gears mate 11/12 → The ball screw 16 → The nut 15 drives the saddle to move. ② The wire traveling system (See to figure 4-2) Motor M → The coupling → Rotation of the wire winding drum → The gear mate 17/18 → The gear mate 19/20 → The screw22 → The nut 21 drives the saddle of the wire winding drum to move to-and-fro. ③ The taper driving system (See to figure 4-3) U direction: The control system sends out a movement pulse → The step motor E → The gear mate 10/9 → The screw 5 → The nut 4 drives the U saddle to move. V direction: The control system sends out a movement pulse → The step motor B → The gear mate 6/8 → The screw 7 → The nut 3 drives the V saddle to move. ④ The up-arm driving system Manual or Motor driving → The worm → The worm wheels mate → The screw → driving the up-arm move up and down to change the span.

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5. Controller

The controller figure (Pls. refer to the actual controller if technology update)

The machine electric, the NC system and the pulse supply are integrated an integer in the controller box. The touch buttons are used in the operation panel of this kind of machine. About its program and operation, please refer to the operation manual of ”WEDM program and control system”.

WCUT-2010 component

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5.1 About WCUT-2010 control system. The electrical discharge machining happened between the electrode (which normally is Molybdenum wire or Tungsten and Molybdenum alloy wire) and the workpiece by using of the high frequency impulse power supply and the high peak current to bring high heat and high energy to erode the workpiece.

WCUT-2010 WEDM Control system platform is a new and predominant controller in China, which is designed by us at recently. The transducer control wire cutting directly in WCUT-2010 WEDM Control system to realize balance and stability for the changing direction of wire-winding drum, also reduce the problem of control unit to improve the performance of WEDM. WCUT-2010WEDM Control system keep the merits of XKG-2005 and have bring improvements in machining productivity and workpiece surface rough. There are some technologies first used in High-speed WEDM in China.

There are some circuit elements in WEDM software interface card. For example, the X,Y,U,V axis step motor interface circuit , high frequency pulse output control circuit, high frequency sampling input circuit, auto-pause on machining over output circuit and parameters chosen circuit.

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The driving circuit of X, Y, U, V motor The driving circuit of X, Y, U, V motor are disposed of the dictates that come from “WEDM circuit board” control card to display the message in LED and to drive the motors to run.

The control main board The wire-running control circuit, pump control circuit, high frequency power supply control circuit, wire-broken alarm circuit, stroke procetion of wire-running motor circuit, switching off high frequency on wire-winding drum change direction circuit, wire-running motor speed control circuit, long or short wire traveling control circuit, high frequency pulse grouping control circuit, high frequency monofier circuit (the pulse width, pulse interval and power pipe adjustment.), machining parameters chosen circuit, machining power supply chosen circuit and single side discharging chosen circuit are included in the control main board.

Pulse power board The pulse power board is used for amplifying the pulse-message that come from the pulse monofier board to accomplish electrical discharge between the workpiece and the electrode. About the failure prompt When wire broken is happened during machining, the controller can switch off the wire traveling motor, the water pump and the high-frequency power supply; and then send a warning alarm. At this time, there is a failure prompt flashing on the VGA display, only because the controller system can’t receive the sampling message and retreat it as a short circuit happening. On the other hand, you should solve the corresponding problem at once. When machining is over, the controller can also switch off the wire traveling motor, the water pump and the high-frequency power supply and wait the next dictate.

5.2 About control panel

There are 5 bottoms on the control panel of WCUT-2010, please check how and when to use them

as below.

(During machining, customers can adjust parameters and function according to actual situation)

No. Name and

symbol Function and use When to use Remark

1

Wire- running

on / left move

cursor

Open wire-running or left

move cursor for choosing

different function

Open

wire-running

or choose

different

parameters

When LED doesn’t blink, it is used to open

wire-running; when

press “OK”, the LED

blinks, it is used to left

move cursor to choose

different function

2

Wire-running

off / increase

Close wire-running or increase

parameters

Close

wire-running

or choose

different

parameters

When LED doesn’t blink, it is used to close

wire-running; when

press “OK”, LED

blinks, it is used to

increase parameters

3

Function Key

compound function choose key

To choose

different

function

Press “OK”, LED

blinks, use others

buttons to change and

adjust parameters

4

Open pump /

reduce

Open pump or reduce

parameter, move downward

Open pump

and change

paramters

When LED doesn’t blink, it is used to open

pump; after press “OK”,

LED blink, it is used to

reduce parameters.

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Turn off

pump/right

move

Turn off pump or right move to

choose different

parameters/function

Turn off

pump /

change

parameters

or function

When LED doesn’t blink, it is used to close

pump; after press

“OK”, LED blinks, it is

used to right move to

choose different

parameters or functions

5.3 About the parameter choosing on control panel For operating WCUT-2010 expediently, we prepared 15 groups parameters in the control system. The group 1 parameters are used for machining 40mm height workpiece to get good surface rough on once cutting. From group 2 to group 7, the parameters are used for machining repeatedly. From group 8 to D, the parameters are used for machining 10mm~500mm different height workpiece on once cutting. The group E and F parameters are used for machining 20mm and 40mm height workpiece to get high machining efficiency on once cutting.

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All those parameters only for reference.

Item Power Pulse width

Pulse interval

Wire-travel

Grouping pulse

Wire-running

speed

Workpiece thickness (mm)

Machining efficiency

（mm2/min）

1 3 8 7 6 8 1 40 40

2 1 2 8 6 3 3

3 2 2 8 6 3 3

4 2 4 8 6 4 2

5 3 16 8 6 4 2

6 4 36 8 6 5 1

7 5 40 8 6 5 1

From item 2 to 5, it’s used for lasting cutting. Item 6 is used for sidestep shape workpiece cutting. Item 6 or 7 are used for the firt cutting. All these items only for 40mm height workpiece cutting on machining repeatedly.

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8 4 8 6 9 6 1 10 45

9 3 8 7 6 6 1 20 45

A 4 12 8 6 7 1 40 50

B 5 16 8 6 7 1 60 60

C 4 20 8 6 7 1 100 40

D 5 60 9 F 8 1 500 40

E 5 40 7 6 8 1 20 80

F 5 50 8 6 8 1 40 85

5.4 About the electrical cabinet operation <1> About power supply

The electrical cabinet is connected with 3-Phase AC 380V/50HZ power supply. The PE must has good connection and sound contacting.

Open the front door of electrical cabinet, push switch QF located on cabinet right side to top position to make it electrifying.

Close front and back doors of cabinet. (“Switch off on open doors” safe switches are used here.)

Turn the red emergency stop button on clockwise to make sure that it’s on start position

Turn switch VK on cabinet on clockwise to position 1. Press down Power ON/OFF key on control panel ( ) then the AC contact

KM1 contacting, light on the digital display area and the fan start running. Make the computer power on, then HF system will be displayed on screen.

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If you don’t use the machine for a long period, please let the power off; but if you don’t use it for a short time, you also can make switch VF to position “0”! <2> Wire-running system

Pushing down the button ( ) on the control panel, then the indication light on wire-running panel and the indication light LZ on BAOMA-3 PCB turn on. At the moment, the wire traveling motor starts to run. If you push down the button ( ) again, then the wire traveling motor stop running.

The reciprocation of the wire traveling is under the control of the position limit switch (SQ1 and SQ2). If SQ1 acting, then LF on BAOMA-3 PCB turn off and LK2 flash. If SQ2 acting, then LF is still on but LK3 flash.

There are 4 groups for wire-running speed control. Group 1 is for high speed. When you choose it then the indication light LH and LL on BAOMA-3 will turn off. Group 2 and 3 is for middle speed. When you choose 2 then LH turn on and if you choose 3 then LL turn on. Group 4 is for low speed. If you choose it then LH and LL turn on together.

Transducer control the wire running speed to make it running smoothly and in a good condition. When wire broken protection component and stroke protection switch SQ3 acting, the wire-running switch is no function and buzzer alarm. At this moment, you should eliminate above mention problems to make it work.

<3> About machine electric Press down pump ON/OFF key on control panel ( ) then the indicator light

on pump panel and indicator light LSB on BAOMA-3 PCB turn on, which indicates that the water pump starts to run. On the contrary, pushing down the button ( ) again then the water pump stops running.

During the wire traveling motor running, pushing down the button ( ) then the indicator light on high frequency panel and indicator light LGP on BM-3 PCB turn on, which indicates that the high frequency is outputting, whereas no high frequency happening.

When high frequency started, the control system will control the high frequency directly. During this time, about 105V or 85V value will be displayed on the voltage meter. If you switch off wire-running then the pump and high frequency will stop at the same time.

The wire-running start and stop buttons are set below the wire-winding drum to convenience the operation.

When winding, please set wire-running speed on middle or slow position!

About setup parameters on the transducer, please refer to accessory sheet.

Warnings:

1. The parameters of the transducer are setup by manufacturers or professional technicians. Do not change it; otherwise the machine may be out of work.

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2. If you change the parameters of the transducer or disassembly it and make the machine or the transducer out of work, we will not be responsible of repair it for free.

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6. The pulse power supply 6.1 Summarize “WCUT-2010 “ pulse power supply is a high-efficient electrical discharge unit, which is designed by us recently. The pulse supply is an integrated circuit, which can keep the pulse frequency steady and improve the performances of anti-jamming. High-power CMOS tubes, which are used by parallel connection make it can output strong current to improve machining efficiency. There is a outputting of grouping-pulse wave in “XKG-2005” system, which is suitable for machining the parts of low thickness and high surface roughness. The following is the main technical and technologic guidelines in “WCUT-2010” system.

The voltage of power supply: 3-AC 380V 50Hz The peak voltage of pulse: ≤DC105V The pulse parameters: See to item 1 and item 2. The surface rough μm

(Material: Cr12, Quench,40mm; single cutting& productivity=30 mm2/min) Ra≤2.5 (Material: Cr12, Quench,40mm; several times cutting& productivity=40 mm2/min) Ra≤1.2

The best machining efficiency: ≥100mm2/min (Material: Cr12, Thickness: 40mm~50mm)

The Max. Machining thickness: 500mm The Max. Machining current: 6A

6.2 Principle “XKG-2005” system is composed of the DC monofier unit, the front large unit, the power large unit and the sampling unit. (See to figure 6-1)

Figure 6-1

The front large unit is consisted of integrate circuits (MC4049) to make sure that CMOS driving tubes work on a good condition. 6.3 About parameters choosing on multi-times machining

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Low-speed WEDM cutting principle which is multi-times and different energy discharging cutting is used in WCUT-2010 control cabinet to get good workpiece surface rough. Dimension calculation method about multi-times cutting. For example: A 12mm square workpiece which need thrice cutting; Material:Cr12; Height:40mm; Mo. Wire: Φ0.18mm. You can setup the machining parameters according to the following items: Clearance compensation value: 0.09mm; First offset value:0.07; Twice offset value:0.02; Thrice offset value:0mm. After machining, check the dimensions. If it is 0.02 lower than 12mm, please set the clearance compensation value again which should be (0.09+0.02/2)=0.10mm. On the other hand, if the dimension is 0.02 higher than 12mm, please set the clearance compensation value: (0.09-0.02/2)=0.08mm. The cutting parameters are different from different material, different thickness and different Mo. Diameter. Operator should get the best parameter from actual work.

Note: Normally, the last cutting offset should be 0mm!

6.4 About multi-times machining Because the Mo. Wire electrode should be discharging repeatedly, the wire must be waste with more cutting, which makes the wire thinner and thinner. It must cause to decrease the machining precision. For Φ0.18mm wire, the max. cutting area is about 20000 mm2. It’s a suggestion that you should measure the diameter of wire before machining and you should tighten the wire after cutting guiding path. If find the wire diameter waste so much, please change it! You also should care about the following points:

Check the wire vibration when wire running not cutting. (refer to chapter 12) Check whether the wire cut into the electrified block or not. Check the working fluid. Run your cutting program on software simulation to check your programme. It’s better to keep more supporting to decrease material deforming.

Some phenomena on workpiece cutting surface after machining. Trace on surface. It’s a hint that wire maybe vibrate, material maybe deform,

parameter setup for offset value maybe not correct. Black spots happen on two side on cutting area. It’s a hint that the working

fluid is not good for work. After cutting, please clean it with oxalic acid then rinse it. Dry it with white

cloth and coat it with antirust.

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7. Transportation Before transportation, make sure to loose the bolts which connect screw nut to the saddle and the fixing parts that connect the top saddle and the middle saddle, the middle saddle and the machine body. During transportation, to avoid some unstable factor, such as bump badly, incline etc. when crane transporting the unpacked machine; make sure the hook and the steel wire is reliable. When transporting machine wood box, soft steel wire should be used to firm the box and there are some attentions:

No inversion, side and incline too much. Packing firmly when transportation. When crane transportation the box, make sure the steel wire hook the box

firmly and hang on the hook of the crane (See to figure 19 <a>, 19 <b>). When slinging or letting down, you cannot incline it and bump box bottom or side, jerk, surge and shake.

After the box is freighted to the aim place, take off the bolts of the cover and disassembly it first. Before installation, don’t disassembly the baseboards at once, you should inspect whether the machine is scathing or not first and check all the accessories according to the packing list and register the checking result.

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8. Installation About configuring the groundwork, please refer to the following figures and sheets.

The groundwork is suit to all the types on the following table:

Type Width a(mm) Length b(mm) DK7732 940 1516 DK7740 1070 1676 DK7750 1100 1960 DK7763 1400 2040 DK7770 1570 2085 DK7780 1630 2205

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This groundwork figure is suit for DK77100 WEDM. (Refer to the following table.)

Type Width a(mm) Length b(mm) DK77100 2660 3375

DK77100C 3660 3375 Before installation, please use clean silk cloth dipping kerosene to clean the resisted-rust oil layer, especially, on the ball screws, guide ways, the guide wheels etc and some important parts. And make sure there is not dirty. After do this, please smear machine oil (HT-30) to avoid rust and lubricate all moving parts. When installation, please install working table and machine body first. The machine installation orient should be up against nature light and there are no hard vibration, strong power, magnetic field and noise around it. Otherwise it may influence the machine normal working. If the circumstance is not sound, you can adopt vibrate resisted groundwork to isolate vibration source and you must apart the firm board when rotate the handle. After the machine is fixed in the groundwork, inspect it by using of tow horizontal meters, which is put on the portrait of the working table and the value of portrait and transverse must be less than 0.04/1000 then adjust the parallelism and perpendicularity of the hang arms to the working table. The machining belongs to precious machine; which is in good working condition about the temperature of 20±5℃. Don’t put it beside with a heavy machine together and avoid vibration source.

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9. Adjustment Before running the machine, the machine must be fixed firmly and lubricate is plentiful, the connection of bolts and nuts is firm. There are not barriers around the machine and you must clean the ball screws and guide ways. To make sure that the electric wire and the ground wire are connected reliably then there is no oil leaking. 10.1 About the span adjustment You should set up the equal span according to the machining thickness of the workpiece. We suggest that the perfect distance between nozzle 2 or nozzle 3 and the workpiece is 5mm to 10mm. You can use angle rule or the molybdenum wire adjustment gauge to adjust the molybdenum wire in a vertical position. Before you adjust the perpendicular, you should loose the fixing screw on the taper saddle and then rotate the knob of the step motor. After adjustment, please tighten the fixing screw on the taper saddle.

! Attention: Before adjusting, please loose the locking screws between the up-down arm and the column.

About operating and adjusting big taper mechanism please see to figure 9-1. It is composed of the linear bearing 1, the connected shaft 2, the driven shaft 3 and the lengthened shaft 4 (See to the figure 9-2). The locking screws connect the driven shaft and the connected shaft. The shafts moving relatively to the linear bearing accomplish the swing motion. The moving precision of the linear bearing and the shafts is so high that the big taper mechanism can work steadily and the precision can be kept for a long period. Before the operation and adjustment, please read the following items:

1) When using the driven shaft and the connected shaft to compound to work, adjust the central distance of the guide wheels within the range of 141mm to 296mm.

2) When using the driven shaft 1, connected shaft and lengthened shaft 4 ( L=159mm) to compound to work, adjust the central distance of the guide wheels within the range of 280mm to 435mm.

3) When using the driven shaft 2, connected shaft and lengthened shaft 4 ( L=298mm) to compound to work, adjust the central distance of the guide wheels within the range of 435mm to 578mm.

During machining, the shaft should be higher to the top of the linear bearing about 50mm to keep the enough moving distance of the linear bearing. About adjustment the central distance of the guide wheels, please refer to the following steps:

1) The central distance of the guide wheels ≤ 280mm; Loose the locking screws between the up-down arm and the column. Loose the locking screws of the connected shaft and take out the shafts. Rotate the up-down screw to drive the up-down arm to a new and proper

position. (If motor drives the up-down screw, please push the up or the down button to realize the operations.)

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Assembly the shaft to the linear bearing and the driven shaft, and keep the shaft should be higher to the top of the linear bearing about 50mm.

Fix the locking screws between the connected shaft and the driven shaft. 2) The central distance of the guide wheels ＞ 280mm

Loosen the locking screws between the up-down arm and the column. Loosen locking screws connecting between the upper and lower bracket

and connected shaft at the connected shaft device. Rotate the up-down screw to drive the up-down arm to a new and proper

position. (If motor drives the up-down screw, please push the up or the down button to realize the operations.)

Attention: Before do this, please loose the locking screws between the up-down arm and the column.

Choose the proper compound of the connected shaft and driven shaft according to the expected length. And assembly the shaft to the linear bearing and the driven shaft, and keep the shaft should be higher to the top of the linear bearing about 50mm.

Attentions: When the up-down arm is driven from the top position to the bottom position, to be sure to disassembly the connected shaft.

Warnings: About the span adjustment, please read the instructions carefully. Otherwise we will not be answer for it.

10.2 The guide wheels adjustment (refer to figure 9-3) Adjust screw 7 and nut 6 to eliminate the axial clearance of the guide wheels. When adjustment, you should make sure that the guide wheels rotate smoothly and there is not axial clearance. When change the guide wheels, please lubricate the guide wheels and the bearings. 10.3 About the clearance on the working table When assembly the machine, we have been adjust the clearance to a reasonable range. So customers should not adjust it again.

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10. Operation Be familiar with the machine components and the use of controller before running the machine. The following is the adjustment methods: 11.1 Turn on the power supply and run the machine without any load. To observe

whether it runs normally or not. The normal items include: The controller must work well more than 10 minutes. The machine component work well. The pulse power supply and the machine electric work well. The action of all stroke switches is sensitive. The pipe system of the working liquid system is smooth and the pressure is

normal. 11.2 Injecting lubricate according to the machine lubricate rules. 11.3 Add or change the working liquid every 10 to 15 days. 11.4 Fixing the workpiece.

Verify the perpendicularity between the electrode wire and the working table then to fix the fixture on the working table.

Clean the surface of fixture and workpiece then make sure that the conduct electricity is reliable.

When fixing the workpiece, you should find out the datum plane to make sure that the workpiece is parallel to X or Y direction of the working table by using of the centesimal meter according to the drawing. The position of the workpiece should be fit for the cutting range and the workpiece and the fixture should not touch any parts of the wire traveling unit.

11.5 Coiling the electrode wire. The wire running speed setup

Transducer is adopted in the wire traveling system of the machine. Please choose wire-running speed to “2” or “3” on coiling wire. When cutting, normally we choose the speed to “1”.

The tension setup The manual coiling wire is applied, so you should adjust the tension according to practice.

Before startup the machine, please adjust the stroke rams to both sides. Coil the electrode wire around the protruding axis of coiling wire part, firm the button, make it passing the wire let wheel to wire winding drum and pin it by a bolt. At this time, rotate the wire-winding drum to terminal position. Coil it several circle and push down wire-running ON/OFF button to make the indicator light turn on, and then run the wire traveling motor to coil the other terminal. When finished, stop the wire traveling motor and cut off the end of the electrode wire. Hang the wire tip on the wire let wheel, the wire-keeping bar, the electrified block, the wire guide wheel, etc. then return it to the wire winding drum, pin it and coil it reverse direction for several circles.

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Tightening wire The electrode wire may loosen only because of elasticity fatigue. After a long time working, so you need tighten wire again by manual. Notice that the force for tightening wire should be even. .

Coiling wire The wire traveling route of the 0°and 6°taper: (See to figure 10-1) The wire winding drum → The wire let wheel → The up wire guiding stick → The electrified block → The up guide wheel → The down guide wheel → The electrified block → The down wire guiding stick → The wire broken protection stick → The wire winding drum.

The wire traveling route of the 30°and 60°taper: (See to figure 10-2) The wire winding drum → The wire broken protection stick →The up wire let wheel → The down wire let wheel →The down guide wheel → The up guide wheel The up wire let wheel → The down wire let wheel → The wire winding drum. Adjust the stroke rams again to keep the distance to two sides is about 5 to 10mm. You should take care that the turning direction of coil and the direction of the wire traveling saddle to prevent overrun.

Wire running control panel

Attention: Taking off the handle when the wire traveling, which can avoid dangers. The wire traveling stroke limit is adopted by a method of the screw and the nut separated. The tail of the screw is

smooth, so when overrunning, the motor is in racing condition. Pushing the wire traveling saddle and rotate the wire winding drum to make the screw mate the nut to resume work.

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11.6 Operation steps

Turn on the power supply. Input the machining program. Adjust the span of the wire guide frame according to the workpiece

thickness. Fix the fixture. Coil the electrode wire. (When finished, tighten the wire once to twice and

the force should be even.) Choose the equal wire traveling speed. (It is determined by the workpiece

thickness and you cannot change the wire traveling speed when machining.) Turn on the wire traveling motor. Turn on the water pump and adjust the flux. (Before turning on the water

pump, you should close the adjustable valve. After running the water pump, open the valve gradually to make sure that the electrode wire is embodied by the water column.)

Turn on the high-frequency power supply and choose the electrical parameters. (User can choose the electrical parameters according to the cutting efficiency or surface roughness. When cutting in, please draw the clearance of the pulse and after cutting in, adjust it to meet machining request.)

Run the program. When cutting in, adjust the knob of the adjustable resistor to make the hand of the current meter stably. (The current meter shaking gently is allowable.)

When machining is over, turn off the pulse power supply first and then the water pump and the wire traveling motor. To check whether the X, Y coordinate arrive at the end-point or not and take off the workpiece from the workpiece and rinse it to check it.

Attentions: There is a red emergency stop button on the controller panel. Push down the button when emergency to stop the machine.

11.7 Taper machining

Loosen the firm bolts of U, V saddle. Adjust the span then the perpendicularity of the electrode wire. Measure the central distance (H2) between the up guide wheel and down

guide wheel and the distance (H1) between the down guide wheel and fixture, then the workpiece thickness (H). (See to the following figure) Input the value of H, H1, H2 and r into the program system to generate automatically the machining program. (Detail, please refer to “Program system user guide”.

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The clearance adjustment of the screw mate on the taper cutting mechanism. (See to the following figure) Open the top and bottom cover of the taper cutting mechanism and loose or tighten the screw mate by a spanner to make the screw mate rotate flexibly and no clearance in axial direction.

Clearance adjustment of the screw mate

Attention: As new machine, clearance adjustment of screw mate have been finished in our company. So you need not adjust it by yourself.

Workpiece

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11. About the usage of wire guider 11.1 Scope The wire guiders are standard parts for equipping with XKG-2005 WEDM. You can find the functions of wire guider on the following items:

It’s a guider to guiding wire to minish wire-running vibration, so it can improve the workpiece cutting surface rough.

It can realize ≤1.5° taper cutting on 100mm height workpiece. 11.2 Structure About the structure of wire guider, please refer to the following figure 11-1.

1. Wire guider house 2. Wire guider 3. Wire guiding block 4. Cover 5. M4x15 Blot 6. M4x30 Blot 7. Hinger 11.3 Requirement and installation The wire guiders have been correctly equipped and adjusted before sale out. Customer can use it directly. If you disassembly it, please follow the following steps to set it up.

Take off water spraying part. Check the position of up and down guide wheels to make sure two guide wheels

in one plane and center to center through the middle line of wire guider house. Coil wire and tighten wire, calibrate wire perpendicularity (Both X and Y axes).

After adjusting, do not move the guide wheels. Assembly wire guider on wire guider house. Refer to wire guider structure figure. Make wire through the wire guider from up guide wheel to down guide wheel.

When wire goes through the wire guider, please make the wire front as straight as possible.

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Tighten wire then check the wire perpendicularity. If needed, please adjust the

position of wire guider a little bit. You can loose 2 pcs M4x15 blots and adjust the wire guider then fix the two blots.

Check parallelism of wire guider bottom surface with micrometer. It should be ≤0.01mm.

Connect water pipes.

11.4 Some important items about wire guider After adjusting wire guider component, it should be no changing on whole

machining. Otherwise it will affect on normal cutting work, especially on taper cutting. Sometimes, when making taper cutting, operator adjust U,V servo axes to keep wire and workpiece perpendicular. That’s forbidden! If you find wire is not perpendicular with workpiece, you should adjust workpiece not the wire!

If you want get high surface rough and making multi-times cutting, it’s better to use wire guider component. If making normal cutting, you can use normal way which is guide wheel working with spraying part. The spraying part belongs to spare parts.

If assemble wire guider component, it will affect on taper cutting. So you only can make ±1.5° cutting with wire guider component. If you want to

make ± 3.0° cutting, please disassemble wire guider component and using spraying part!

28

12. Usual problem and solution 12.1 Black screen

a. Check the EMS memory card; b. Check the display card; c. Check the fan of CPU; d. Check the slot of CPU; e. Check the fan of UPS; f. Check the input voltage; g. Check the power supply;

12.2 Wire broken and agglomeration a. When machining, the molybdenum wire touch the workpiece and then the

wire broken. At the same time, there is forceful arc between the molybdenum wire and the workpiece. So you should check the IRFP250 power tube and BYW29 diode on the BM2005-1 board.

b. When machining, the saddle of wire winding drum can’t change the moving direction immediately to make the wire broken. So you should check whether the bolts on the travel ram are firm, whether the position-limited switch is good and whether the close contact can be reset. Also you should check the indicator light on BM2005-3 PCB is light on or no?

c. When machining, the molybdenum wire broken suddenly. Please check the jumping range of the let wire wheel and the guide wire wheels.

d. When machining, the molybdenum wire let-running is abnormal. So you should check if there is clearance on wire drum portrait or broken happened on the bearings of wire drum.

e. Check if there is small contacting resistor between electrified block, wire running drum, wire letting wheel and machine body. If happened, clean it.

f. Working liquid problem, so you should change it. g. The quality of molybdenum wire is not good.

12.3 No voltage a. Check if the IRFP250 CMOS power tube on BM2005-1 PCB is broken ; b. Check whether there is a voltage on bridge of the high frequency circuit; c. Check whether the resistances of the high frequency circuit is good; d. Check whether the software controlling high frequency ON of HF interface

card is good or not; e. Check whether the +5v and +12v indicator lights on BM2005-3 PCB is

lighting or not; 12.4 Normal wave but no motion feed

a. The circuitry of the high frequency sampling is not good; b. Following adjustment is not on a good condition; c. There are some failures on the software interface card;

12.5 No enough moment output or no rotation for step motor. a. DC24v on BM-2 PCB working good? b. The connector plug of the step motor is loose;

29

c. The indicator light on BM-2 PCB is lighting or no when single step moving; d. There are some failures on the software interface card; e. The current-limiting resistance of the driving circuit is out of work; f. Mechanism failures, such as gears or the axis of the motor are locked.

12.6 The wire traveling motor failure a. When machining, no changing motion direction. So you should check the

travel position-limited switch and the middle relay; b. Can’t startup the wire traveling motor and buzzer alarm

Check wire-running ON/ OFF key on control panel or wire running button on wire running panel. If only one of two is ok, then check the wire connection of the failure one. If both of them is out of work, please check wire broken protection switch, heat relay and stroke protection switch of wire-running motor.

Check the indicator light on BM2005-3. If it’s ok, then check the alarm signals of transducer. Otherwise, restart machine again and see what’s happened? If it’s same problem, it’s a hint that BM2005-3 PCB is out of work.

c. Noise happened on the wire-winding drum. So you should check whether there are plentiful lubricant on the bearings, the screw and the nut.

d. Check if there are some blocks between screw and nut, or gears? 12.7 Usual problem about machining

a. The low surface quality of the machining part. Check the machining parameters; Check molybdenum wire quivering; Check the tension of molybdenum wire; Check the working fluid; Check whether the guide wheel and the wire let wheel is normal; Check the transducer setup.

b. When machining big thickness workpiece, that short circuit, unstable machining current and voltage is normal.

So you can check the machining parameters; Adjust the transducer to make machining current stably; The wire is too tighten; Spraying water is normal or no? The material is easy to deform or not? The wire waste too much.

c. The low machining precision of machining part. Check the missing step of the step motor; Check the jumping range of the guide wheel and the wire let wheel; Check the quivering of the molybdenum wire; Check the clearance of the saddle driving and the deforming of the

workpiece.

30

12.8 Mechanism problem a. The perpendicular error of the saddle. So you should adjust the V shape guide

way of the up saddle; b. Noise on the wire-winding drum. So you should change the bearing of the

wire traveling unit; c. Noise on changing motion direction of the wire-winding drum. So you should

change the bonds or the elastic block on the wire traveling driving system; d. Clearance on the wire-winding drum. So you should check the screw, the nut

and the bearings and then eliminate clearance or change bearings. 12.9 Stripe on the machining surface of the workpiece

a. The electrode wire is loose or quivering. So you should tighten the wire again or change the guide wheel and the wire let wheel;

b. The machining following is not unstable. So you should adjust the high frequency parameters and the following speed again;

c. Unqualified material about the workpiece. So you should change the workpiece.

12.10 Wire quivering a. The electrode wire is loose. So you should tighten the wire again; b. The precision of the bearing and the guide wheel is reducing for a long period

running. So you should change the guide wheel and the bearing. c. The impact and jumping range are enlarging for a long period running. So you

should adjust the wire-winding drum. 12.11 Jumping and inflexible motion about the guide wheel

a. The axial clearance of the guide wheel is increasing. So you should adjust the clearance of the guide wheel;

b. The side jumping of the guide wheel is increasing. So you should change it not adjust it;

c. The working liquid permeates through the bearings. So you should rinse it with the gasoline or change it;

d. The precision of the bearings and the guide wheel falls for a long period running. So you should change it.

12.12 Wire broken a. The electrode wire is aging and fragile. So you should change the qualified

electrode wire; b. The electrode wire is too tight and quivering hardly. So you should change the

electrode wire or the guide wheels; c. No enough working liquid to drain the iron-scraps. So you should adjust the

flux or change working liquid; d. Incorrect choice about the high frequency parameters to the workpiece

thickness. So you should setup the equal parameters; e. The clearance is increasing when the wire winding drum changes motion

direction. So you should adjust it again; f. The travel position limit switches are fall to make the saddle of the wire

traveling overrun. So you should check it and change or adjust it;

31

g. Oxidation skin on the surface of the workpiece. So you should get rid of the oxidation skin;

12.13 Wire loosening a. Winding the wire is not good. So you should tighten it again; b. It can be loose after a long period working. So you should change it.

32

13. Maintenance Before running the machine, you must be familiar with the lubricating system and lubricating rules (See to figure 13-1 and 13-2) to ensure the machine performance and usage life. There are oil cups and oil holes to the lubricate points and the lubricating method is manual timely. (About the lubricating rules and attention, please refer to the appendix table 1.) Keep clean to the machine and oil the lubricating point if the machine has stop for 8 hours. The electrified wheels and the wire-let wheels of the taper cutting mechanism unit should be rinsed frequently. After rinsing, the dirty oil can’t be flow into the backwater slot of the working table. The guide wheels and bearings must be replaced in general after 3 to 4 months using. If the working liquid system is jammed, dredge immediately. Otherwise the liquid will permeate through machine, which can destroy the electric components. The machine is equipped with wire protecting unit. Do away with the waste electrode wire once wire broken. Isolate the machine from outside vibration and strong magnetic field and keep clear in the workshop. When the power supply is ±10% higher than rated voltage, the controller should be connected with steady voltage power supply or adjustable voltage device (3N-280V3KW). On the condition that the machine runs two shifts every day and operated as the rule, its precision can keep for two years. The time that the machine needs heavy repairing is not less than 8 years.

33

14.Consumable component catalogue Code Item Quantity Position Remarks

3201 The guide wheels 2 The wire traveling unit

4 bearings (D25) for 1 set of guide wheels

3202 The wire letting wheels for single

support

2 for little taper or no

taper WEDM 4 for big

taper WEDM

The wire traveling unit

2 bearings (624) for 1 set of guide wheels

3203 The wire letting

wheels for double support

1 The wire traveling unit

4 bearings (624) for 1 set of guide wheels

3204 The electrified blocks 2 The wire

traveling unit

3205 5×15 red gem bar 1

Wire broken protection

unit

3206 2.5×20 red gem bar 2 Wire support

unit

3207 The elastic block 1 The wire traveling unit

3208 The flush boards 1 The guide wheel house

It’s different from different taper WEDM

Attention: The model of the consumable components will be subject to technical

updating.

34

15. About machining parameters choosing Different machining parameters lead to different machining result. There are also a lot of factors influence on the machining quality. For example, different requirements of precision and surface rough, different molybdenum wire, different working liquid, different operator, different workpiece material, different material heat treatment, different cutting servo speed, etc. The following mentioned only for reference. You must choose or use it according to actual machining conditions. IP—Power tube ON—Pulse width OFF—Pulse interval FZ—Grouping pulse HX—Wire traveling (long/short) Power supply:3 phase AC380V/50HZ Material: Cr12, Thickness:10mm, Working liquid: saponification liquid, Molybdenum wire: φ0.18mm Parameters for once cutting:

Item IP 0N 0FF FZ HX V A frequency conversion Efficiency

1 2 6 7 — — 60 1.2 3 20

2 3 5 9 — — 70 1.6 3 40

3 3 8 7 — — 70 2 3 50

4 4 20 6 — — 75 3 3 60

5 5 45 7 — — 75 3 3 70

Material: Cr12, Thickness:20mm, Working liquid: saponification liquid, Molybdenum wire: φ0.18mm Parameters for once cutting:


1 2 8 6 — — 60 1.2 3 20

2 3 5 8 — — 70 1.6 3 30

3 3 8 7 — — 65 2 3 45

4 4 20 7 — — 80 2.5 3 60

5 4 20 6 — — 75 3 3 70

6 5 40 7 — — 75 3 3 80

7 6 50 7 — — 75 4 3 90

35



1 3 5 7 — 4 65 2.4 3 25

2 3 5 9 — 6 65 2.3 3 30

3 3 10 7 — — 60 2.2 3 40

4 4 22 7 — 6 60 2.7 3 50

5 6 12 8 — — 60 2.5 3 60

6 5 35 8 — — 65 3 3 70

7 5 35 7 — — 65 3.3 3 80

8 5 50 7 — — 70 3.5 3 90



1 5 6 8 — 4 70 2 3 30

2 4 10 8 — 8 60 2.5 3 40

3 5 15 7 — 6 65 2.7 3 50

4 5 20 8 — — 65 3 3 60

5 5 25 7 — — 60 3.3 3 70

6 6 25 7 — — 65 3.5 3 80

7 7 45 8 — — 70 4 3 90

36



1 3 25 8 — 8 60 2 10 40

2 5 15 8 — 8 65 2.5 8 50

3 5 25 8 — — 65 2.8 10 60

4 5 20 8 — — 65 3 8 60

5 5 45 8 — — 65 3.3 8 70

6 6 45 8 — — 65 3.5 8 80

7 7 50 9 — — 65 4 10 90

Attention: <1> The frequency conversion can be adjusted according to the changing of current meter!

<2> To improve surface rough, you can increase the value of FZ, but you must lose machining efficiency!

Material: Cr12, Thickness:10mm, Working liquid: saponification liquid, Molybdenum wire: φ0.18mm Parameters for thrice cutting: Cutting

sequence IP 0N 0FF FZ HX V A frequency conversion

Off-set

Wire speed

Efficie-ncy Remark

1 5 40 7 — — 75 2 3 0.07 1 —

2 3 8 8 — — 75 1.2 3 0.02 2 —

3 2 2 8 2 — 65 0.8 3 0 3

45

Low pressure

Material: Cr12, Thickness:20mm, Working liquid: saponification liquid, Molybdenum wire: φ0.18mm Parameters for thrice cutting: Cutting


Off-set

Wire speed

Efficie-ncy Remark

1 5 40 7 — — 75 3 3 0.07 1 —

2 3 8 8 — — 70 1.2 3 0.02 2 —

3 2 2 8 — — 60 1 3 0 3

45

Low pressure

37

Material: Cr12, Thickness:40mm, Working liquid: saponification liquid, Molybdenum wire: φ0.18mm Parameters for three cutting: Cutting


Off-set

Wire speed

Efficie-ncy Remark

1 5 40 7 — — 65 3.5 3 0.07 1 —

2 3 8 8 — — 65 1.2 3 0.01 2 —

3 2 2 8 — — 60 1.5 3 0 3

40

Low pressure



Off-set

Wire speed

Efficie-ncy Remark

1 5 40 8 — — 70 3.5 3 0.06 1 —

2 3 8 8 — — 65 1 3 0.018 2 —

3 2 2 8 — — 60 1.2 3 0 3

40

Low pressure



Off-set

Wire speed

Efficie-ncy Remark

1 5 45 8 — — 60 2.5 4 0.07 1 —

2 3 8 8 — — 65 1 4 0.015 2 —

3 2 4 8 — — 60 1.4 4 0 3

40

—

38

Material: Cr12, Thickness:10mm, Working liquid: saponification liquid, Molybdenum wire: φ0.18mm Parameters for five times cutting: Cutting


Off-set

Wire speed

Efficie-ncy Remark

1 5 40 7 — — 60 2.5 4 0.09 1 —

2 3 16 8 — — 65 1.5 4 0.05 2 —

3 2 4 8 — — 60 1.1 4 0.02 2

35

—

4 2 2 8 — — 60 1 4 0.01 3 —

5 1 2 8 — — 50 0.6 4 0 3 Low pressure



Off-set

Wire speed

Efficie-ncy Remark

1 5 40 7 — — 60 3 4 0.09 1 —

2 3 16 8 — — 65 1.5 4 0.05 2 —

3 2 4 8 — — 60 1.1 4 0.02 2

35

—

4 2 2 8 — — 60 1 4 0.01 3 —

5 1 2 8 — — 50 0.8 4 0 3 Low pressure



Off-set

Wire speed

Efficie-ncy Remark

1 5 50 7 — — 55 3.2 4 0.09 1 —

2 3 16 8 — — 65 1.8 4 0.05 2 —

3 2 4 8 — — 65 1.5 4 0.02 2

35

—

4 2 2 8 — — 60 1.3 4 0.01 3 —

5 1 2 8 — — 50 0.6 4 0 3 —

39



Off-set

Wire speed

Efficie-ncy Remark

1 5 40 7 — — 55 3.5 5 0.09 1 —

2 5 40 7 — — 65 1.8 4 0.05 2 —

3 3 16 8 — — 65 1.5 4 0.02 2

35

—

4 2 2 8 — — 60 1.3 4 0.01 3 —

5 1 2 8 — — 50 0.6 4 0 3 —



Off-set

Wire speed

Efficie-ncy Remark

1 6 45 8 — — 55 3.5 5 0.10 1 —

2 5 40 7 — — 65 1.8 4 0.06 2 —

3 3 16 8 — — 65 1.5 4 0.03 2

35

—

4 2 4 8 — — 60 1.3 4 0.01 3 —

5 2 2 8 — — 50 0.6 4 0 3 —

40

Appendix:

The lubrication list Table A: Lubrication No. Lubricating points Lubricating methods Lubricating period

1 The trapezium screw of wire traveling unit

Oil storage slot lubricating

Once a half year

2 The saddles, guide ways of the wire traveling unit

Oil gun injection Once a shift

3 The gears to wire traveling unit Oil gun injection Once a shift

4, 5 The ball screws of X, Y ZG-2 lubricating grease GB491

Once three months

6, 7 The guide ways of X, Y Oil gun injection Once a week

8, 9 The gears to X, Y ZG-2 lubricating grease GB491

Once a half year

10 The screws of U, V ZG-2 lubricating grease GB491

Once a week

11 The gears to U, V ZG-2 lubricating grease GB491

Once a half year

12 The up-and-down screw and worm wheel

Oil gun injection Once a week

13 The up-and-down guide way Oil gun injection Once a week

Attentions When lubricating the points of 2, 6, 7, 12, 13, you should open the protecting cover first. (See to figure 13-1 and13-2)

Table B: The list of gears, screws and nuts No. Item Parameters Material Heat treat Q. Position Remarks

1 Screw Tr20×3 45 1 The wire traveling

frame General

2 Worm wheel

M=1.5 z=28, α=20°7-d Tr20×3 JB179

ZQSn6-6-5 1 The wire traveling

frame General

M10 SQn6.5-0.1 2

The taper cutting

mechanism

C, D series

3 Nut

M18×1-4h SQn6.5-0.1 2

The taper cutting

mechanism

E, F, G, H series

M10 45 2

The taper cutting

mechanism

C, D series

4

Assistant nut

M28×1-4h 45 2

The taper cutting

mechanism

E, F, G, H series

41

No. Item Parameters Material Heat treat Q. Position Remarks

M10 40Cr C30 1

The taper cutting

mechanism

C, D series

5 Screw

M18×1-4h 40Cr C30 1

The taper cutting

mechanism

E, F, G, H series

M=0.4 z=24, α=20°6-d GB2363

40Cr Solution

heat treatment

1

The taper cutting mechanism

C, D series

6 Gear M=0.5 z=24, α

=20°6-d GB2363

40Cr Solution

heat treatment

1


E, F, G, H series

M10 40Cr C30 1

The taper cutting

mechanism

C, D series

7 Screw

M18×1-4h 40Cr C30 1

The taper cutting

mechanism

E, F, G, H series

M=0.4 z=50, α=20°6-d GB2363

45 Solution

heat treatment

1


C, D series

8 Gear M=0.5 z=100, α

=20°6-d GB2363

45 Solution

heat treatment

1


E, F, G, H series

M=0.4 z=50, α=20°6-d GB2363

45 Solution

heat treatment

1


C, D series

9 Gear M=0.5 z=100, α

=20°6-d GB2363

45 Solution

heat treatment

1


E, F, G, H series

M=0.4 z=24, α=20°6-d GB2363

40Cr C30 1


C, D series

10

10

Gear

Gear

M=0.5 z=24, α=20°6-d GB2363

40Cr C30 1


E, F, G, H series

11 Gear M=0.6 z=24, α

=20°6-e GB2363

40Cr Solution

heat treatment

1 The working table

General

12 Gear M=0.6 z=112, α

=20°6-e GB2363

40Cr Solution

heat-treatment

1 The work table General

13 Ball screw

FFZD4004-P3-875×725 GCr15 C58-62 1

The working table

General

42

No. Item Parameters Material Heat treat Q. Position Remarks

14 Ball nut GQ4004 GCr15 C58-62 2 The working table

General

15 Ball nut GQ4004 GCr15 C58-62 2 The working table

General

16 Ball screw

FFZD4004-P3-1045×895 GCr15 C58-62 1

The working table

General

17 Little Gear A

m=1 z=34, α=20°7-f GB2363

40Cr Solution

heat treatment

1 The wire traveling

unit General

18 Big Gear B

m=1 z=117, α=20°7-f GB2363

Bakelite 1 The wire traveling

unit General

19 Little Gear B

m=1 z=34, α=20°7-f GB2363

40Cr Solution

heat treatment

1 The wire traveling

unit General

20 Big Gear A

m=1 z=117, α=20°7-f GB2363

Bakelite 1 The wire traveling

unit General

21 Nut

components

Tr22×3-8 QSn6.5-0.1 1 The wire traveling

unit General

22 Screw Tr22×3-8 45 T365 1 The wire traveling

unit General

23 Gear m=0.6 z=24, α

=20°7-f GB2363

40Cr Solution

heat treatment

1 The

working table

General

24 Gear m=0.6 z=112, α=20°7-f

GB2363 40Cr

Solution heat

treatment 1

The working

table General

25 Worm m=1.5 z=1, α

=20°7-f GB2363

45 HRC28 1 The wire traveling

frame General

Attentions: The length of the ball screw is different from different model machine. Table C: The length of the ball screw to different model machine

Model L1 L2 L3 L4

DK7732 565 430 645 510

DK7740 645 510 745 610

DK7750 745 610 875 740

DK7763 875 725 1045 895

DK7770 955 820 1325 1190

DK7780 1135 1000 1325 1190

DK77100 1362 1184 1587 1409

43

Table D: The list of bearings and motors No. Item Model Specification Rank Q. Position Remarks

A Cone ball bearing

51203 GB/T301 15×35×12 D 1 Worm

wheel General

45BC340 Front and hind axis 1 C、D series

B Step motor 55BC340 1

The taper saddle E、F、G、

H series 618/8

GB276 8×16×4 D 2 C、D seriesC

Single row angular ball

bearing 7003C GB276 17×35×10 D 4


H series 618/8

GB276 8×16×4 D 2 The taper screw C、D series

D Single row angular ball

bearing 6002-2Z GB276 15×32×9 D 2

Front bearing house

E、F、G、H series

45BC340 Front and hind axis 1 C、D series

E Step motor 55BC340 1


H series

F Single row angular ball

bearing

6203 GB276 17×40×12 C 1

Hind bearing house

General

G Single row angular ball

bearing

7005AC GB292 25×47×12 C 2

Front bearing house

General

H Single row angular ball

bearing

7005AC GB292 25×47×12 C 2

Front bearing house

General

619/4 GB276 4×11×4 D 4 General

I

Single row angular ball

bearing

624 GB276 4×13×5 D 4

The guide wheels General

K Single row

angular ball-bearing

6004 GB276 20×42×12 D 2

Wire traveling

unit General

L Single row

angular ball-bearing r

7203 GB/T292 17×40×12 E 2

Wire traveling

unit General

M AC motor

YSD712 4/8 B5 1

Wire traveling

unit General

N Single row


6004 GB276 20×42×12 D 2

Wire traveling

unit General

619/4 GB276 4×11×4 D 2 Wire let

wheel General O

Single row angular ball-

bearing 624 GB276 4×13×5 D 2 The guide

wheel General

P Step motor 90BC5100A 1 Working

table General

Q Step motor 90BC5100A 1 Working

table General

R Single row


6203 GB276 17×40×12 C 1

Hind bearing house

General

44

Table D: The transducer introduction (Panasonic) 1> Switch on the power supply then the number “0.0” will display on the CRT. 2> Push down the “MODE” key, the number change to “00.”. Then push down “∨” key about ten seconds and don’t release, the message “Setup parameter” will appear on the CRT and you can use the key “∨” or “∧” to setup the parameter that you want. 3> Push down the “MODE” key, number “00.” will appear and push the key “∧” to change the number to “99_”. After do this, please push the “MODE” key again to appear “01_”, when you can use the key “∧” to choose the sequence. 4> Push down the “MODE” key, then the key “∨” to change to “00”. After do this, please push down the “MODE” key again and then push ““∨” or “∧”to setup the correct parameters. You can setup the parameter according to the following table. The parameter table about transducer setup:

Sequence Code Setup value Sequence Code Setup value

01 00 25 11 25 100

02 01 50 12 26 2.0

03 16 TEr 13 27 POS

04 17 PnL 14 36 100

05 18 2 15 37 1.0

06 21 2.0 16 46 Fsrs

07 31 0.5 17 51 STbL

08 19 100 18 55 rEu

09 22 5.0 19 60 0-F

10 32 5.0 20 30 0

Note: If the keys of the transducer was not touch about 3 seconds, the transducer system will return to the monitor condition. So you should

push down “MODE” key to change this condition.

45

Table E: The transducer introduction (Emerson) 1> Press [PRG] key to enter programme system, which will display the current

function code (Such as: F000). 2> Press [UP] or [DOWN] key to change the function code that you want. 3> Press [FUNC/DATA] key to enter the corresponding parameter value. 4> Press “movement” key to change current cursor position. 5> Press [UP] or [DOWN] key to change parameters that you need. 6> Press [FUNC/DATA] key to save the parameters that you choose. 7> Press [PRG] key to exit programme condition. If you need more information about operate Emerson transducer, please refer to Emerson TD900 manual book. The parameter table about transducer setup ( do not change it!):

Sequence Code Setup value Sequence Code Setup value

01 F000 0 11 F029 150

02 F002 1 12 F030 0.6

03 F012 0.4 13 F031 30

04 F013 0.6 14 F058 36

05 F019 0 15 F059 25

06 F024 0.1 16 F060 10

07 F027 2 17 F071 1

08 F028 5 18 F088 0

Note: You must setup F088 first, switch off power supply then setup parameters in order!

46

Appendix:

P24 23 11

14

H

16

G

15

F

13

12

Q

Figure 4-1 The driving system of working table

2221

O I

M N

L 20 1719 18 K

Figure 4-2 The driving system of wire running unit

47

4

4

7

3

3

5

C

E

8 6

D

B

9 10

Figure 4-3 The driving system of taper unit

Figure 9-1 The taper adjustment

48

Figure 9-2 Wire frame connector and it’s adjustable range

Figure 9-3 Adjustment about the guide wheel

49

Figure 10-1 The wire traveling path about 0° and 6° WEDM

Figure 10-2 The wire traveling path about 30° and 60° WEDM

50

Figure 13-1 The lubrication points about 0° and 6° WEDM

51

Figure 13-2 The lubrication points about 30° and 60° WE

52

Component Distribution Diagram of Controller

53

Control Panel Circuit Connect Diagram of Front Door

54

Circuit Connect Diagram of Front Door

55

Circuit Connect Diagram of Back Door

56

Interior Circuit Connect Diagram

57

Power Supply

58

The Stepping Drive of X, Y, U,V

59

Schematic Keybutton Diagram

57974927 dk7740 d

Engineering

machine body

machine type

machine structure

machine weight

machine functions

machine figure

fields of machine industry

different type machine