TECHNOLOGY DOCUMENTS
SERIAL NUMBER:
1. USER’S MANUAL 2. PARKING LIST 3. WARRANTY CARD
1. USER’S MANUAL 2. PARKING LIST 3. WARRANTY CARD
MACHINE: ZGEDM
DK7740A
INSPECTION CERTIFICATE
MANAGER (SIGN) INSPECTOR (SIGN)
DK77 Series EDM Wire Cutting Machine
User's Manual
NOTICE 1. We provide one year warranty for machine principally. 2. Service contents: Mechanical and electrical malfunctions under normal working environment and correct operations. 3. Please pay attention during warranty: 1) Any problems caused by input voltage problem (input voltage must be 380V 20V) are not in warranty. 2) Any problems caused by nature disaster like fire, flood or thunder are not in warranty. 3) Any problems caused by operation mistakes are not in warranty. 4) Users should not add any new peripheral in the computer, change any devices in the computer or modify the operation system. Problems caused by virus are not in warranty. 5) If above cases occurs, we have to charge when provide the service. 6) The wear parts on the machine are not including in warranty. 7) (Wire cutting machine’s wear parts: pulleys, guide wheel, conductor block and etc.)
INSTALLATION Dear user, Kindly please under the instructions to install the machine properly after you open package: 1. Please check all items on the parking list. 2. Please read the manuals and technology documents carefully before you start the machine. 3. Please take off all block junctions on the machine, sweep the seal grease and lubricate all parts of machine. 4. Please adjust the level of machine’s work table. 5. The power supply must be 3 phase 380V 50Hz voltage. Please connect the PE terminal to protect earth for safe. Otherwise we do not take charge of any electrical shock.
Part 1 Machine Introduction DK77 series CNC EDM Wire Cut is consisted with machine basement, worktable, wire drum, wire shelf, working fluid circulation system and machine electric and CNC system. The CNC controls worktable running in X, Y direction according to the post accurately. The wire runs cyclically from the wire drum to upper and lower guide rollers in high speed. There’s high frequency pulse electron discharging between wire and workpiece on machining, the discharging path generates high temperature to erode metal. The ashes of melted metal are washed out by the working fluid. There’s place to install taper device (Option) on the front of wire arms. The taper device can rotate wire in U and V direction. The machine can perform interpolation movement in X,
3. Wire System The wire system controls molybdenum wire running cyclically along t he path consisted by wire drum, upper rollers and lower rollers. The wire drum i s made in a thin cylinder that insulated with drum spindle. It rotates in 11m/s linear velocity to send out the wire and runs on guides go and back to keep the wire route in the proper position. The wire drum changes running direction when touch limit switches. This circuit of limit switches is simple, high response, low noise and long life. There’s another over travel switch to stop machine running only if the limit switches are out of work. The wire shelf is consisted by column, fixed arm, mobile arm and guide rollers. The carbide conduct blocks are installed on the front of fixed and mobile arms respectively. And
The pump on working fluid tank deliveries working fluid via valves to muzzles in the front of arms to shoot work fluid to workpiece from up and down sides at same time when machining to wash out the ashes of metal. The working fluid drops in the box gutter flume then flows back to tank. And the dirty working fluid could be filtered and settled in it . Please clean the tank in time. The working fluid is mixed by WEDM soap scream and clean water in rate 1:20.
4. Operation Notices 1. The wire is powered by electricity when machining, it may cause people be shocked if touch on it. The operator shall take essential protection wares and do NOT touch the discharging parts when machining.
7. Check the wire tension before machining. If the wire is losing, tighten it by the tools in time. 8. Put on the protection cover on wire drum and close the door of cabinet before machining. Do NOT take off the cover to avoid wire throw off if wire broken. 9. Start the wire drum first and check if it runs well, then turn on the pump, and turn on high frequency at last to start machining. Turn off them backwards when finished.
5. Runs Machine in Good Conditions The principle factors to influence machining precision and methods t o improve machining precision: Apparently, the machine motion precision influences the working result precision
已磨损
正常 Fig-1
(2). Check conduct blocks: The conduct blocks are made i n carbide, please check if there’s slot on it before machining. If the wire is inserted into the slot, please rotate it to change the touch position or change the blocks. (3). Check the backlash in X, Y ball screws: The backlash would change after a long
(Ton), time off (Toff) and other parameters to get a stable condition. Normally, operators choose big Ton on roughing to increase the cutting speed, and small Ton on finishing. Keep the current stable to keep the cutting speed regularity to guarantee the machining results. (3). Relationship of discharging gap and working fluid: The diff erence from working fluid components, the resistances, wash out abilities and dielectric abilities of fluid are different. All these factors can change the gap. So in finishing, the operator must choose a proper gap composition when posting the program.
3. Method to decrease workpiece distortion: The principle sequence for finishing steel parts on WEDM shall follow the steps: raw material, forging, anneal, rough machining, quenching, temper, grinding, EDM wire cutting, handcraft by locksmith. There’re 2 chances in this machining linkage to make big distortion and influence cutting precision. The material
切割孔类工件变形情况
切割加工后钢材变形情况
Fig-2
On the right of Fig-2, we illustrate a distortion on machining part with a hole. During the machining of cutting the square hole, because of the stress inside material, the square hole would be like a tambour in dot line or a saddle in dash line. Sometime the distortion would
A. Arrange the cold and heat steps properly to prepare for the heat treatment as last to decrease the stress and distortion. For high precision parts, temper the part in how temperature after cutting to stable the size. B. Do not cut the mold from outside of workpiece directly but make a hole to though the wire beside the edge of workpiece. And the cutting range should not near the workpiece edges to guarantee there’s enough intensity on workpiece to against the stress inside. See Fig-3.
穿丝孔 坯料 尺寸一般在
若凸模轮廓尺
workpieces and the parts would not distort after cutting. For some low hardenability materials, this technique keep and increase the shape harden and improve the quality of mold. E. Choose the start point near workpiece’s gravity center and clamp it properly. When cutting to the closed point, the workpiece would distort little. F. Add some supports in proper position for big workpiece to decrease the distortion caused by the gravity of cut down part. G. For small parts and long semi-manufacture parts, there’re too much factors to avoid all distortion. In this case, we suggest users adopt check and cut mixed method, measure the part during machining and modify posting program in time to get the design demands.
4. Analysis of cutting surface: The metallographic analysis and surface hardness test
6. Lubrication System No
Lubricate part
Frequency
Method
Oil
1
X axis ball screw
Every day
Oil gun
30# Oil
2
Y axis ball screw
Every day
Oil gun
30# Oil
3
X axis screw nut
Every day
Oil gun
30# Oil
4
Y axis screw nut
Every day
Oil gun
30# Oil
5
Wire drum linkage
Every day
Oil gun
30# Oil
6
Wire drum screw nut
Every day
Oil gun
30# Oil
7
Wire drum guides
Every day
Oil gun
30# Oil
ATTENTION: 1. Change the high speed grease on the guide rollers every 2 weeks 2. Change other bearings every half year
8. Machine Maintenance Often clean the machine is the best way to keep the machine precision and long life, improve work efficiency. Please taking care the following matters: 1. Lubricate the machine with clean oil in time according to the manual. 2. Move all movable parts by hand to check if all in good condition before turn on the machine. 3. The machine shall work in environment temperature 5-35°C, humidity 40-75﹪, air pressure 86-110KPa. In order to get the best cutting result, keep the temperature constantly about 20°C. 4. Clean the machine after working and put on grease on the easy rust parts. Clean the
Part 2 Mechanism 1. Machine Tool Usage EDM wire cutting machine DK-series consists of Numeric Control，High Frequency Power Generator and Machine Body. This machine tool i s used to process metal dies， patterns and mechanical parts used in electronic apparatuses, precision machines, commercial industry and military industry etc, with high precision, high stiffness and high toughness.
2. Machines Specifications Machine Type
DK7732
DK7740
DK7750
DK7763
DK7780
3. Machines Operational Part No
Name
Function
1
Wire drum travel limit fork
Adjust the width of wire
2
Operation Panel
Refer to next charpter
3
Valves
Adjust upper/lower muzzles
4
Hand wheels of X, Y axes
Move the worktable in X, Y axes
4. Operating and Adjustment 1. Preparation before working: -
Turn on the power switch and check the machine tool working status.
-
Fill or change the cooling water.
-
Check the Molybdenum wire
-
Keep the guide rollers run fluently and stable. Attach lube on the bearing when change the rollers.
6. Operating steps: a. Turn on the computer b. Type in the post program c.
Start the Molybdenum wire drum motor
Don't turn on discharge. Please check the stress of the Molybdenum wire now. d. Turn on the water pump There are a line of drains on the lower arm, please keep it clean. e. Set the pulse width The pulse width influences the efficiency, accuracy and roughness. Choose a set of
5. Troubleshooting No Troubles
1
2
3
Causes
Wire dent on 1. wire is loose the workpiece 2. the table is not balance surface 3. cut tract is not stable 1. wire is loose 2. V-channel on the pulleys wear out Wire shaking 3. vibration during turn direction 4. wire is bended 1. too wide in the pulley bearings Rollers run 2. trashes go into pulleys not agility 3. pulleys and bearings
Solutions
1. stress the wire or replace the wire 2. check the table 3. adjust the parameters
1. 2. 3. 4.
stress the wire or replace the wire replace the pulleys and bearings adjust or replace the spindle replace the wire
1. adjust the pulley 2. wash the pulleys in the coal oid 3. replace the pulleys and bearings
6. Wear Parts Part Name
Quantity
Installed Position
Conduct Block
3
Upper/lower wire arms
Guide roller assembled
2
Upper/lower wire arms
Wire drum junction
3
Connection drum and motor
Muzzle
2
Upper/lower wire arms
Part 3 Electrical The machine electrical equipments take the role of controlling wire drum’s motor running and directions, pump running, wire broken protection and other protection functions. For more details, please refer to the Electrical Schematics.
Parameters set This kind of machine is upgraded from high speed wire cutting, but it is completely different from the controller. It is upgraded parameter setting to computerized from IC digital setting, upgraded wire running speed to variable from constant. These upgrades realized multiple cutting in finishing surface performance. But there’re a lot of factors that influence the finishing result besides pulse parameters, discharging parameters. These factors
High frequency pulse No.3, 2 and 1
Ton (us)
Toff
Power
Inverter （Hz）
No.3 for rough cutting
7
2
7
2
No.2 for first trimming
10
1
15
4
No.1 for finishing trimming
13
1
15
6
Attention: The bigger Ton, the higher efficiency and bigger discharging gap. The smaller Ton will make machining stable but lose efficiency. The bigger current will get big cutting velocity but lower the stability and increase wire’s wear. The lower servo voltage, the higher efficiency but may not stable. The higher Inverter (Hz) can wash out ashes faster and make machining
1. Plugs Definition 30PIN PLUG Pin No.
Label
Comment
Pin No.
Label
1
PE
Ground
16
05
2
24V1
17
03
Drum motor off led
18
12
Drum change direction 1 (NO)
4
19
AL2
Emergency Stop
5
20
02
Drum motor on(NO)
6
21
13
Drum change direction 2 (NC)
Lamp power 3
24V2
Comment Drum motor off (NC)
20PIN PLUG Pin No.
Label
Comment
Pin No.
Label
Comment
1
PE
Ground
11
YB
Yellow
2
12
YC
Blue
3
13
YD
White
4
14
YE
Black
5
XA
Red
15
UA
6
XB
Yellow
16
UB
7
XC
Blue
17
UC
8
XD
White
18
VA
9
XE
Black
19
VB
10
YA
Red
20
VC
4PIN PLUG
U axis
V axis
Signals for controller on PCI slot (25PIN) 1
XA
14
UA
2
XB
15
UB
3
XC
16
UC
4
XD
17
VA
5
XE
18
VB
6
YA
19
VC
7
YB
20
TK0
8
YC
21
TK1
9
YD
22
PJD1
10
YE
23
PJD0
11
12V-
24
PM-
12
PJD2
25
PM+
13
12V+ TK0, TK1, TK2 are stop condition signals. TK0, TK1 are normal open (NO); TK0, TK2 are normal closed (NC).
15 PIN SLOT(J7)
Mitsubishi Inverter
Tyco Inverter
Comment
1
RUN
SYN+
A: frequency level
3
C
RELAY
B: alarm signal
4
SE
SYN-
A: Cut off high frequency when direction changing
5
SD
COM
COM
6
B
TRIP
B: out put relay
10
STF
FWD
Motor runs CW
11
RL
SP1
Frequency segment No.1
12
RM
SP2
Frequency segment No.2
13
RH
SP3
Frequency segment No.3
14
PC
FM+
15
STR
REV
2
7 8 9
Motor runs CCW
2. High Frequency Board Schematics C J 3 O N 1 1 0 0 9 8 7 6 5 4 3 2 1
1 9 8 7 6 0 5 4 3 2 1
1 V U I 1 2 N 3
L E D
G N D V 7 8 L O 0 U 5 T
D 2
4 7 0 u F / 2 5 V
+
C 4 6 7 0 u F / 2 5 V
+
2
C 5
B R V I D + G E 2 V -
F F U 1 S E 1
D A 1 C
4
4 V C C
2 C 0 1 1 0 M
R 1
1 2 1 1
2
R 9
D 3
U 1 B
1 1 3 4
U C R 5 K C L S K T I N H
K 1 -1 6
K 1 8
K 1 6
1 6
8
6
K 1 T I P 5 2 1 -2
R 1 1 2 0 K
9
V C C
F O U T 1 1
D 4
1 6
6 F O N R 1 1 0 2 0 K
7
8 F O N 2
8
1 1
5
1 5
C 3 1 5 R 0 0 K
U 1 0 A
1 9 0
4 0 1 4 MY 1 2 H z
V C C
2 R 2 6 0
R 8
1
U 1 0 B
1 3
4 0 1 7
3
1 0 4
4 . 7 K 4 . 7 K
3
R 7
KK 1 1 -4 8 -
KK 1 1 -1 6 6
1 C 0 4 9 1 8 C 0 4
A C
2 V C C
3 K
1
+
2 2 C 2 0 u F
V C C
4
1 3 F F O U T
K 1 -4
6
4
1 3 R 4 1 0 0 K
K 2
D B 2 5 1 / 4 1 / 6 1 / 8
C Q Q Q Q Q Q Q Q Q O Q 9 8 7 6 5 4 3 2 1 0 1 1 7 4 2 3 2 1 1 9 6 5 1 0
J U
J 1
1 3 2 1 2 3 1 1 1 1 3 6 1 4 7 1 5 8 1 6 9 1 7 0 2 8 2 4 2 5 1 9 2 2 0 1 2 4 1 2 5 V C AB B AC C C B A C
D
C C B BA A
P 6
P 5
P -4
P 3
P -2
P -1
1 1
9
3. Power Board 1 3 5 7 9
8 7 6 5 4 3 2 1 4 D 0 ? C / 4 G C B / B A / A V 9 D -1 N D D N N D / D E / E C F / F C 9 0 1 1 1 1 1 6 1 1 1 2 3 4 5
F F
2 4 6 8 1 0
7
J 1 1 1 2 3 4 5 6 7 8 9 0
C C B B
A A
D F E D F E
V C C
E E 1 1
5
C O N 8
D D 9
C C 1 4
3
7
B B 9
A A 1 1
5
U 1 A 4 0 4 9
U 0 4 2 4 B 9 4
U 2 E 1 2
4 D 1 4 I F 2 R 8 4 1 0 F
4 0 4 9
U 0 4 2 4 C 9 6
U 2 D 1 0
4 D 1 4 I E 2 R 8 4 1 0 E
4 0 4 9
U 0 4 2 4 A 9 2
U 2 F 1 5
4 D 1 4 I D 2 R 8 4 1 0 D
4 0 4 9
U 0 4 1 4 C 9 6
U 1 D 1 0
4 D 1 I 4 C 2 R 8 4 C 1 0
4 0 4 9
U 0 4 1 4 B 9 4
1 4
3
U 1 E 1 2
4 D 1 4 I B 2 R 8 4 1 0 B
U 1 F 4 0 4 9
2
4 0 4 9
1 5
4 D 1 4 I A 2 R 8 4 1 0 A
4. Central Control Board C J 1 O 0 N 1 1 9 8 7 6 5 4 3 2 1 2 1 2 1 1 0
1 1 1 9 8 7 2 1 0 6 5 4 3 2 1
B 2 0 V
B AB B AA 4 1 - 4 - A 6 - 6 - 0 - 1 -1 B B A 0 0 5 2 V 1 V 5 V 6 2 2 1 -2 V -1 V 0 0 0 V V V 0 2 V V
A 2 -2 0 V 2
3 D 1 A B C
A C
B R V I D G E
V +
4
B 5 0 V
A 5 -1 2 V
3
2
D 1 A A C
KK MM -P -F
B 4 0 V
R 5
+ 1 C 0 2 0 0 V U u I 1 F N / 5 0 V G N 3 D V O U 7 T 8 2 4 4 7 0 u F / 5 0 V 4 R 7 1 0
+ C 3
C 4 A P
2
+ 2 4 V L E D D 1 1
+ C 5
C 6
6
J 5 _ 1 6
9
1 1
1
1 2 0 / 0 . 5 W
R 4
C 9
J 5 _ 1 1
2
4
1 6
1 3
K M -P
8
6
J 5 _ 1 7
J 5 _ 2 0
9
1 1 +24V
+ 1 2 V L E D D 2 2
K 3
J5-6
1
4
1 3 J 8 5
J 8 C O N 1 6
9 1 1 2 0 1 3 1 1 4 2 1 5 3 1 6 4 1 7 5 1 8 6
1
+ 1 C 0 1 0 0 V U u I 2 F N / 5 0 V G N 3 D V O U 7 T 8 1 2
R R E ? S 1
8
J 5 _ 1 3
F 2
1
4 7 0 u F / 5 0 V
J8_10
J 5 _ 1 5
K 2 1
1 2 3 4 J8_5 5 6 7 8 9 10 11 B6-0V 12 J8_13 13 J 5 -1 PM- 14 15 9 PM+ 16
s y n / s e
C 1 0
V +
4
+24V
1 9 8 7 6 0 5 4 3 2 1
K M -F
1 6 2 A
J J P A 9 5 J 4 _ 8 _ 6 D -1 2 V J 5 _ 1 4
A C
B R V I D G E
1
AB 1 1 -1 0 1 V 0 V 1 2 0 / 0 . 5 W
C J 9 O N 1 1 9 8 7 6 5 4 3 2 1 0 0
B 6 0 V
A 6 6 V
J5_11
1 2 3 4 5 6 7 8 9 10 11
J 5 C O N 2 0
5. Buttons board 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 1 3 4 1 1 5 6 1 1 7 8 1 2 9 0
C J 1 O N 2 2 1 1 1 1 1 1 1 1 1 1 0 0 9 8 7 6 5 4 3 2 1 0 9 8 7 6 5 4 3 2 1
J J J J J J J J I I I I -1 I -1 I -1 I -1 I 7 5 J J 7 J 5 J 3 J 1 J 9 J J + I I I 2 -2 9 I -1 I -1 I -1 I -1 1 I -1 8 6 4 0 8 6 4 2 0 V
A L 2
A L 1
Part 4 Operation and post program 1. Parameters list 15
14
13
12
11
10
9
8
7
6
5
4
3
1
2
3
4
6
8
12
16
24
32
48
64
96
7
6
5
4
3
Set Toff to 0 when use single trip cut function
2
1
0
128 192 256 2
1
Ton (μs)
0 Toff
1:2
1:3
1:4
1:5
1:6
1:7
1:8
1:9
31
15
7
3
1
0 Power
1
2
3
4
5
6
7
6
5
4
3
2
1
Inverter
10
20
25
30
40
50
60
(Hz)
2. Post the trim program (Cut once and trim twice) 1. Draw the part’s shape, like the circular drawing in blew picture:
Drawings above process are graphic for assistant purpose
Drawings to be processed
3. Set the total times of cutting and trimming:
Set the times of CUT. Only cut once, set it to 1; and cut 3 times, set it to 3.
5. Go to the working screen and read out the posted program:
High frequency
Power on the
switch
step motor (J)
Read out the saved post
Servo sensitive
6. Set Parameters before Machining 1. Go to the parameter list from working screen:
Go to the parameter list
3. Go to the next menu:
Get into the parameters setting
MACHINE: ZGEDM
DK7740A
PACKING LIST
DK77 SERIES
1 PAGE
EDM WIRE CUT
PAGE 1
No.
ITEMS
QUANTITY
COMMENTS
1
Machine tool DK7740A
1 set
2
Machine foot and foot bolt
3
Crank for wire drum
1 set
4
Breakwater cover for wire drum
1 set
5
Wire tension adjuster
1 set
6
Clamp
1 set
Installed on machine
7
Water muzzle
1 set
Only for taper device
8
Vertical guage
1 set
9
Guide rollers installation tool
1 set
4 pairs
MACHINE: ZGEDM
DK7740A
WARRANTY CARD
WARRANTY TERMS 1. We provide one year warranty for every machine tool. 2. Please send the warranty card to us after start machines. We will establish user’s profile to provide you the warranty services. 3. When you face some problems of machines, regardless in or out of warranty, kindly please contact us and tell us detailed problems, machine’s information and service place to help us send technician to the machine as soon as possible. 4. All wear parts are not in warranty, e.g. pulleys, bearings, guides and bulbs. Users shall buy the wear parts but no service cost during the warranty period. 5. Please take the warranty card with you when you come to us for exchanging malfunction parts. Users shall under our instructions when change any part on the machine themselves. 6. If problems caused by users transport the machine, add new part on the machine, not care the machine properly or operate the machine not under instructions, we do not take
WARRANTY CARD OF ZGEDM (PART 2) Serial number:
Please send part 2 to our company
CUSTOMER
ADDRESS
MACHINE
MACHINE S/N
MACHINE DATE
DEALER
INVOICE DATE
INVOICE S/N
BANK
ACCOUNT
POST NUMBER
TELEPHONE
FAX
EMAIL
MANAGE DEP.
OPERATE DEP.
REST DAY
CUSTOMER FEEDBACK SURVEY INSTALL RESULT: TECHNICIAN:
DATE:
CUSTOMER’S ADVICE: CUSTOMER (SIGN):
DATE:
