Development of Precision Indexing Shaft for Type 2B EDM Machine The precision indexing axis (C-axis, also known as U-axis) of the B-type EDM machine enables precise angular positioning and continuous rotary servo machining. The C-axis and the Z-axis are linked to process internal and external threads, internal and external helical gears, and the like. The C-axis is linked with the X and Y axes to process complex parts such as racks, drum molds, and woodworking tools. The CNC EDM machine is equipped with a C-axis, which greatly expands its processing range and enhances processing capability. Especially when machining a workpiece with a curved or curved shape, the C-axis can be linked with other axes to machine complex cavities and sections, such as worm gears, worms, and threads, in a three-dimensional space. The C-axis drive system developed by the company consists of core components such as AC servo motor, coupling, harmonic reducer, ceramic bearing and bearing flange. Compared with ordinary gears, harmonic reducers have the characteristics of smooth transmission, low noise, low frictional resistance, good precision and stability, and small backlash. In the assembly process, according to the assembly accuracy requirements, the components are strictly selected and assembled according to the process rules, thus ensuring the final technical specifications, such as rotation accuracy, backlash, shaft and radial runout. The C axis developed by the Institute can achieve high precision, and its main technical indicators: minimum index (resolution): 360/162/000 (8/single step); (backlash: 2.05;) positioning accuracy:
The A2 intelligent precision digitally controlled EDM forming pulse power supply system developed by the Institute consists of a numerical control system, an EDM control system, a power amplification unit, a main loop unit, an automatic adjustment voltage unit, and a motion axis drive unit. The control system mainly includes the following parts: clock control and discharge pulse signal generation part, current and voltage parameter setting part, special processing waveform control part (equal pulse width, step wave), lift knife control part, servo gap and discharge state (voltage The current detection part, the abnormal discharge processing part (increases the pulse, cuts the pulse width, reduces the pulse width, increases the current) and the like. The main circuit unit includes: high and low pressure processing circuits, high and low voltage compound circuits, low loss circuits, super finishing circuits, special material processing circuits, and the like. According to the main circuit and the additional circuit of the pulse power supply, a combination of various waveforms can be obtained, which can be arbitrarily selected for different processing requirements and superimposed on the discharge gap, so that the processed object obtains the best process effect. The power amplifying unit completes power amplification of the processing pulse voltage and current, and is composed of an IGBT power switch tube and a front drive amplifier circuit. The automatic voltage adjustment unit provides stable processing voltage, which is realized by the thyristor rectification automatic voltage regulation loop, and can realize numerical control and various protection functions. The structural block diagram of the precision CNC EDM pulse power system is shown in the figure.
Only by carefully adjusting the servo feed, the gap size is appropriate, in order to maintain a better discharge state, with higher processing efficiency and stronger processing capability. The servo feed control of the EDM CNC system is a more elaborate closed-loop control. Therefore, the high-speed I/O channel design is adopted in the hardware, and the high-efficiency precision digitally controlled EDM pulse power supply system block diagram code and 32-bit CPU instruction code are directly embedded in the software to ensure the high efficiency of software and hardware operation; Some use sophisticated digital hardware circuit design to ensure accurate detection; high-resolution feedback device to ensure system control accuracy. This ensures that the detection system is accurate, stable and reliable, and the servo motor and mechanical system are responsive, accurate, accurate and stable. High-performance control of the discharge servo feed system.
The numerical control system can realize full-closed control, 0.1m mechanical control precision and spindle (Z-axis) to achieve feed speed of 10m/min or more. The detection part of the numerical control system adopts precise digital hardware circuit design to ensure the accuracy of detection; the linear encoder and the high-resolution pulse encoder dual-position measurement feedback servo system are used, and each axis independently detects the actual position during movement, X, Y Z-axis can achieve position detection control with minimum mechanical drive accuracy of 0.1m. Ultra-precise positioning accuracy and repeatability are achieved through the rigidity of the machine and precise servo control.
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