HCD-5 type wire cutting high frequency power supply instruction manual

One. High frequency power supply overview

HCD—5 type wire cutting high frequency power supply adopts time base integrated circuit as oscillating unit, VMOS field effect tube as power amplifier, which has the characteristics of simple structure, convenient operation, stable performance, large output power, fast cutting speed and small loss of electrode wire. It is especially suitable for fast machining of extra-thick workpieces and for finishing with low surface roughness.

two. High frequency power supply technical parameters

1. Pulse width: ti: 8μs~80μs, to: 1~10ti

2, processing voltage: 70V~110V

3, processing current: 0.5A ~ 5A

4, power output: 12

5, the maximum cutting thickness: ≥ 300mm

6, the maximum processing efficiency: ≥ 100mm2 / min

7, the power supply voltage: AC 220 ± 10% V 50 ± 1Hz

three. High frequency power supply working principle

The HCD-5 high-frequency power supply consists of a time-base oscillating circuit, a pulse width adjusting circuit, an interval adjusting circuit, a power amplifier driving circuit, a power amplifying circuit, and a power supply.

The time-base oscillating circuit is composed of a 555 integrated circuit and a peripheral RC circuit. The RC circuit can be adjusted to obtain a high-precision rectangular pulse of stable width and spacing. After preamplification, the VMOS power tube is driven to output a processing signal.

The pulse width adjustment circuit is obtained by selecting a different resistance value from a double-pole five-throw switch, and the adjustment range is 8~80μs; ​​the interval adjustment circuit is determined by the 4.7K potentiometer and the resistance value, and the adjustment range is 1 to 10 times the pulse width. The power amplifier circuit uses 2 VMOS FETs, 5 switches plus resistors, and 12 combinations select to work.

four. High frequency power panel description (omitted)

Fives. High frequency power supply method

The electric discharge wire cutting process is to use the electric spark discharge to produce electrical corrosion phenomenon of the conductive material, which is the result of the combined action of electricity, heat and fluid dynamics. In the process of spark discharge, the pulse voltage is a necessary condition for generating spark discharge, and the high-frequency power source is a high-power high-frequency pulse signal source for generating pulse voltage. It is an important component of CNC wire-cutting machine tools, in use. Learn to adjust the parameters correctly.

(1), the principle of regulation

1. The height of the workpiece is about 50mm, and the diameter of the molybdenum wire is 0.16mm. When cutting, generally set the “voltage adjustment” knob for 2 steps, the “pulse amplitude” switch for 1+2+2 level, and the “pulse width selection” knob. 3rd gear, the middle position of the “interval fine adjustment” knob, the cutting current is stable at about 2.0A (see “Cut Parameter Selection Table” for details of workpieces at different heights).

2. The feed rate (selected by the controller) is selected: after determining the voltage, amplitude, pulse width and interval, first use the artificial short circuit method to measure the short circuit current, then start cutting, adjust the controller's frequency conversion gear and It is best to use the tracking knob to make the machining current reach 70~75% of the short-circuit current.

3. During the cutting process, the switching of each state should be carried out when the wire cylinder is reversed or the high frequency is turned off, and the state should not be adjusted greatly in a single time to avoid broken wire.

4. When the new molybdenum wire is first cut, the machining current selects one-third to two-thirds of the normal cutting current. After cutting for ten minutes, it is adjusted to the normal value to prolong the molybdenum wire usage time.

(two), short circuit current test

Set the "Voltage Adjustment" knob to 2nd gear, the "Pulse Amplitude" switch is turned on 1+2+2, the "Pulse Width Selection" knob is 3rd, the "Interval Fine Adjustment" knob is in the middle position, and the high-frequency output is shorted with a thicker wire (online A piece of tungsten steel with the front end of the arm on the upper guide wheel is a high-frequency output negative pole, the upper edge of the workbench is a high-frequency output positive pole), a high-frequency power supply is turned on, a wire-opening motor is opened, and a high-frequency control switch of the controller is turned on. The ammeter indicates approximately 2.8A

(3) Selection of various parameters

1. Selection of working voltage

Operation method: Rotate the “Voltage Adjustment” knob to select the machining voltage of 70~110V, which is divided into three gears. The voltmeter indication value is the machining voltage value.

Selection principle: The workpiece with a height below 50mm, the processing voltage is selected at 70V, which is the first gear;

For workpieces with a height of 50mm~150mm, the processing voltage is selected at 90V, which is the second gear;

For workpieces with a height of 150mm or more, the machining voltage is selected at 110V, which is the third gear.

2. Working current selection

Changing the "Pulse Amplitude" switch and adjusting the "Pulse Width Selection" and "Interval Fine Adjustment" knobs can change the operating current. The selection of the operating current here refers to changing the adjustment of the pulse amplitude switch.

Operation method: change the on/off state of the five switches of “pulse amplitude”, which can have 12 levels of power output, which can flexibly adjust the output current to ensure the average machining current required under various process requirements. If two switches marked with 2 are turned on, it is equal to 1 switch marked with 1 and marked with 3; the other similarities.

Selection principle explanation: The more the "pulse amplitude" switch is turned on (the more the number of power amplifier tubes is selected), the larger the machining current is, and the processing speed is faster, but at the same pulse width, the machining current is higher. Large, the worse the surface roughness. In general:

For workpieces with a height below 50 mm, the pulse amplitude switch is turned on in the order of 1 to 5, such as 1, 2, 3 or 1+2, 1+3 or 2+2, 1+2+2 or 2+3.

For workpieces with a height of 50mm~150mm, the pulse amplitude switch is turned on in the order of 3~9, such as 3 or 1+2, 2+2 or 3+1, 2+3 or 1+2+2, 3+3, 2+2+3 or 3+3+1, 3+3+2 or 3+2+2+1.

For workpieces with a height of 150mm~300mm, the pulse amplitude switch is in the range of 6~11, such as 3+3, 2+2+3 or 3+3+1, 3+3+2 or 3+2+2+ 1,3+3+2+1, 3+3+2+2, 3+3+2+2+1.

3. Pulse width selection

Operation method: Rotate the “pulse width selection” knob to select the pulse width from 8μs to 80μs, which is divided into five files, which are 8μs for 1st gear, 20μs for second gear, 40μs for third gear, 60μs for fourth gear and 80μs for fifth gear.

Selection principle: When the pulse width is wide, the discharge time is long, the energy of a single pulse is large, the processing is stable, the cutting efficiency is high, but the surface roughness is poor. On the other hand, when the pulse width is narrow, the energy of a single pulse is small, the processing stability is poor, the cutting efficiency is low, but the surface roughness is good. In general:

For workpieces with a height of 15mm or less, the pulse width is selected from 1 to 5;

For workpieces with a height of 15mm~50mm, the pulse width is selected from 2~5 files;

For workpieces with a height of 50mm or more, the pulse width is selected from 3 to 5 steps.

4. Pulse interval selection

Operation method: Rotate the “Interval Fine Adjustment” knob to adjust the pulse interval width. The clockwise rotation interval becomes larger, and the counterclockwise rotation interval becomes smaller.

Selection principle: When the height of the workpiece is high, the pulse interval is appropriately increased to facilitate chip removal and reduce the formation of electro-erosion dirt at the cutting point, so that the processing is stable and the wire is prevented from being broken. Because the interval width is determined by the “Interval Fine Tuning” knob, the interval width is fixed, so to adjust the interval size is to rotate the “Interval Fine Adjustment” knob. When there is a stable high-frequency current indication, when the "interval fine adjustment" knob is rotated, the current becomes smaller, indicating that the interval becomes larger, and when the current becomes larger, the interval becomes smaller.

(4) Cutting parameter table (for reference only)

Workpiece thickness (mm) Processing voltage (V) Electric current (A) Pulse width (range) Interval fine adjustment (position) Pulse amplitude (level)

≤15 70 0.8--1.8 1--5 Middle 3
15-50 70 0.8--2.0 2—5 Middle 5
50—99 90 1.2--2.2 3—5 Middle 7
100—150 90 1.2--2.4 3—5 Interval becomes larger 9
150--200 110 1.8--2.8 3—5 interval becomes larger 9
200—250 110 1.8--2.8 3—5 Interval becomes larger 9
250—300 110 1.8--2.8 3—5 Interval becomes larger 11

Six, high frequency power supply common fault analysis

(1) Phenomenon: The fuse is broken.

Cause: The bridge rectifier of the rectified power supply of the power amplifier circuit is broken down and short-circuited.

(2) Phenomenon: The power supply indication is normal and there is no high frequency current.

Reason: 1. The output line is open;

2. The internal circuit of the high frequency ammeter is open;

3, control loop failure: 1 commutation stroke switch SQ3 normally closed contact nowhere, 2 machine high-frequency relay line break or contact is not connected, 3 controller without 12V output.

4, the oscillation circuit failure: 1 oscillation board without 12V power supply, 2NE555 IC damage, 3 pulse width and interval adjustment switch damage.

(3) Phenomenon: The power supply indication is normal, and the high-frequency short-circuit current is abnormally large.

Reasons: 1. NE555 IC is damaged;

2. VMOS power tube breakdown;

3. The pulse width and interval adjustment switch are damaged.

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