Pulse power supply and pulse modulation method
阅读说明：本技术 一种脉冲电源及脉冲调制方法 (Pulse power supply and pulse modulation method ) 是由 张国伟 于 2020-08-10 设计创作，主要内容包括：本发明提供了一种脉冲电源及脉冲调制方法,其主控模块与采样模块电气连接,主控模块与上位机电气连接,主控模块与驱动放大模块电气连接,驱动放大模块与放电主回路电气连接,采样模块采集材料类型检测和异常放电状态检测所需的放电间隙的间隙电压和间隙电流信号；主控模块接收上位机的加工参数及采样模块的采集到的间隙电压及间隙电流信号,判断当前加工的材料类型及其对应的异常放电状态,根据加工参数生成初始脉冲信号,对不同材料类型及其对应的异常放电状态进行脉冲信号的调制,通过驱动放大模块及放电主回路输出调制后的脉冲信号,用于绝缘-导电多层材料的电火花加工,可针对各层材料的异常放电进行实时调节和消除。(The invention provides a pulse power supply and a pulse modulation method, wherein a main control module is electrically connected with a sampling module, the main control module is electrically connected with an upper computer, the main control module is electrically connected with a driving amplification module, the driving amplification module is electrically connected with a discharge main loop, and the sampling module is used for collecting gap voltage and gap current signals of a discharge gap required by material type detection and abnormal discharge state detection; the main control module receives machining parameters of the upper computer and gap voltage and gap current signals collected by the sampling module, judges the type of the currently machined material and the corresponding abnormal discharge state of the currently machined material, generates an initial pulse signal according to the machining parameters, modulates the pulse signals of different material types and the corresponding abnormal discharge states of the different material types, outputs the modulated pulse signals through the driving amplification module and the discharge main loop, is used for electric spark machining of insulating-conductive multilayer materials, and can adjust and eliminate abnormal discharge of materials of each layer in real time.)
1. A pulsed power supply, comprising: host computer, sampling module, host system, drive amplification module and the major loop that discharges, wherein, host system's input with sampling module's output electrical connection, host system's input and host computer electrical connection, host system's output with drive amplification module's input electrical connection, drive amplification module's output with the input electrical connection of the major loop that discharges, its characterized in that:
the sampling module is used for collecting gap voltage and gap current signals of a discharge gap required by material type detection and abnormal discharge state detection;
the main control module is used for receiving machining parameters of an upper computer and gap voltage and gap current signals collected by the sampling module, judging the type of a currently machined material and an abnormal discharge state corresponding to the currently machined material, generating an initial pulse signal according to the machining parameters, modulating the pulse signal aiming at different material types and the corresponding abnormal discharge states, and outputting the modulated pulse signal through the driving amplification module and the discharge main loop so as to adjust and eliminate abnormal discharge of different materials in the electric machining process.
2. The pulse power supply according to claim 1, wherein the sampling module comprises an abnormal discharge real-time sampling module and a processing material real-time sampling module;
the abnormal discharge real-time sampling module is electrically connected with an I/O port of the main control module and used for providing a discharge state signal for the main control module;
the processing material real-time sampling module is electrically connected with the I/O port of the main control module and used for providing a material type signal for the main control module.
3. The pulse power supply according to claim 2, wherein the main control module is an FPGA controller.
4. The pulse power supply according to claim 3, wherein the main control module comprises a serial port receiving module, an abnormal discharge detection and judgment module, a processing material real-time judgment module, an abnormal discharge control module and a pulse generation module;
the serial port receiving module is used for receiving processing parameters of the upper computer;
the abnormal discharge detection and judgment module is used for receiving the data collected by the abnormal discharge real-time sampling module and generating an abnormal discharge signal;
the processing material real-time distinguishing module is used for receiving the data collected by the processing material real-time sampling module and generating a material type signal;
the abnormal discharge control module is used for receiving the abnormal discharge signal and the material type signal and generating an abnormal discharge control signal;
the pulse generation module is used for receiving the discharge parallel data of the serial port receiving module and the abnormal discharge control signal of the abnormal discharge control module and outputting a modulation pulse.
5. The pulse power supply according to claim 4, further comprising a power conversion circuit;
the input end of the power conversion circuit is used for being connected with an external power supply, and the output end of the power conversion circuit is electrically connected with the sampling module, the main control module, the driving amplification module and the power input end of the discharging main loop respectively.
6. A method of pulse modulation, comprising:
receiving a material type signal and an abnormal discharge signal acquired by a sampling module;
generating an abnormal discharge state control instruction according to the material type signal and the abnormal discharge signal;
and receiving the machining parameters sent by the upper computer, and generating a pulse waveform according to the abnormal discharge state control instruction to realize the discharge machining of the material and the clearing of the abnormal discharge state.
7. The pulse modulation method according to claim 6, wherein the abnormal discharge state control command includes: a cleaning pulse command, a shut-off command, or a hold current machining state command.
8. The method according to claim 6, wherein the material type signal comprises a conductive material signal and an insulating material signal, and the determining method comprises:
acquiring a gap current signal, and judging a gap short circuit state according to the gap current signal;
and acquiring the gap voltage signal, and judging the type of the material according to the gap voltage signal and the gap short circuit state.
9. The pulse modulation method according to claim 8, wherein the obtaining of the gap voltage signal and the determining of the type of the material according to the gap voltage signal and the gap short-circuit state specifically include:
when the gap is judged to be in a short-circuit state according to the gap current signal, judging whether the voltage value of the gap voltage signal is higher than a first preset value or not;
if yes, judging that the processed material is an insulating material;
if not, the processed material is judged to be a conductive material.
10. A method of pulse modulation according to claim 9, further comprising:
when the gap is judged to be in a non-short-circuit state according to the gap current signal, judging whether the voltage value of the gap voltage signal is between a second preset value and a third preset value;
if yes, judging that the processed material is an insulating material;
and if the voltage value of the gap voltage signal is lower than the second preset value, the gap voltage signal is judged to be a conductive material.
Technical Field
The invention relates to the field of electromachining, in particular to a pulse power supply and a pulse modulation method.
Background
The existing electric spark machining pulse power supply judges the abnormal discharge state of the electric spark machining of the conductive material or the insulating ceramic material through a detection circuit and a related program, and adjusts the discharge waveform output by the pulse power supply in real time by utilizing a main control program so as to reduce the abnormal discharge probability in the electric spark machining, and the existing electric spark machining pulse power supply cannot be simultaneously applied to insulating-conductive multilayer structure materials. The dielectric-conductive multilayer structure material is generally composed of a dielectric ceramic layer, an intermediate bonding layer, and a conductive gold. The insulating ceramic material and the conductive material have different spark discharge states and abnormal discharge states during electric spark machining, and the machining of each layer of material has randomness in time due to the side discharge phenomenon. Therefore, the electric spark machining of the material requires a pulse power supply to judge the abnormal discharge state of the insulating ceramic layer and the conductive substrate in real time and adjust the discharge waveform in real time according to the detection result so as to reduce the abnormal discharge probability in the machining.
The existing electric spark processing pulse power supply can only eliminate the abnormal discharge state of the electric spark processing of a single insulating ceramic material or a single conductive material. For the conductive material with the insulating ceramic coating, because the discharge states of the materials of all layers are different during processing, the conductive material has different abnormal discharge state detection and elimination strategies, and the processing time of the materials of all layers has randomness, the existing pulse power supply cannot distinguish two types of materials during processing and the abnormal discharge states thereof in real time, if the hardware and software of the pulse power supply for electric spark processing of the two materials are simply synthesized, the real-time adaptive adjustment and the rapid elimination of the abnormal discharge states during the electric spark processing of the materials of all layers cannot be realized, and the requirements of the surface processing quality of the conductive materials of the insulating layer and the base cannot be met at the same time.
In view of this, the present application is presented.
Disclosure of Invention
The invention discloses a pulse power supply and a pulse modulation method, and aims to solve the problem that the existing electric spark machining pulse power supply cannot simultaneously meet the requirement of correcting the discharge abnormality of an insulating-conductive multilayer material during machining.
A first embodiment of the present invention provides a pulse power supply including: the device comprises a sampling module, a master control module, a driving amplification module and a main discharging loop, wherein the input end of the master control module is electrically connected with the output end of the sampling module, the input end of the master control module is used for connecting an upper computer, the output end of the master control module is electrically connected with the input end of the driving amplification module, the output end of the driving amplification module is electrically connected with the input end of the main discharging loop,
the sampling module is used for collecting gap voltage and gap current signals of a discharge gap required by material type detection and abnormal discharge state detection;
the main control module is used for receiving machining parameters of an upper computer and gap voltage and gap current signals collected by the sampling module, judging the type of a currently machined material and an abnormal discharge state corresponding to the currently machined material, generating an initial pulse signal according to the machining parameters, modulating the pulse signal aiming at different material types and the corresponding abnormal discharge states, and outputting the modulated pulse signal through the driving amplification module and the discharge main loop so as to adjust and eliminate abnormal discharge of different materials in the electric machining process.
Preferably, the sampling module comprises an abnormal discharge real-time sampling module and a processing material real-time sampling module;
the abnormal discharge real-time sampling module is electrically connected with an I/O port of the main control module and used for providing a discharge state signal for the main control module;
the processing material real-time sampling module is electrically connected with the I/O port of the main control module and used for providing a material type signal for the main control module.
Preferably, the main control module is an FPGA controller.
Preferably, the main control module comprises a serial port receiving module, an abnormal discharge detection and judgment module, a processing material real-time judgment module, an abnormal discharge control module and a pulse generation module;
the serial port receiving module is used for receiving processing parameters of the upper computer;
the abnormal discharge detection and judgment module is used for receiving the data collected by the abnormal discharge real-time sampling module and generating an abnormal discharge signal;
the processing material real-time distinguishing module is used for receiving the data collected by the processing material real-time sampling module and generating a material type signal;
the abnormal discharge control module is used for receiving the abnormal discharge signal and the material type signal and generating an abnormal discharge control signal;
the pulse generation module is used for receiving the discharge parallel data of the serial port receiving module and the abnormal discharge control signal of the abnormal discharge control module and outputting a modulation pulse.
Preferably, the power supply conversion circuit is further included;
the input end of the power conversion circuit is used for being connected with an external power supply, and the output end of the power conversion circuit is electrically connected with the sampling module, the main control module, the driving amplification module and the power input end of the discharging main loop respectively.
A second embodiment of the present invention provides a pulse modulation method, including:
receiving a material type signal and an abnormal discharge signal acquired by a sampling module;
generating an abnormal discharge state control instruction according to the material type signal and the abnormal discharge signal;
and receiving the machining parameters sent by the upper computer, and generating a pulse waveform according to the abnormal discharge state control instruction to realize the discharge machining of the material and the clearing of the abnormal discharge state.
Preferably, the abnormal discharge state control instruction includes: a cleaning pulse command, a shut-off command, or a hold current machining state command.
Preferably, the material type signal includes a conductive material signal and an insulating material signal, and the determining method includes:
acquiring a gap current signal, and judging a gap short circuit state according to the gap current signal;
and acquiring the gap voltage signal, and judging the type of the material according to the gap voltage signal and the gap short circuit state.
Preferably, the obtaining the gap voltage signal and determining the type of the material according to the gap voltage signal and the gap short-circuit state specifically include:
when the gap is judged to be in a short-circuit state according to the gap current signal, judging whether the voltage value of the gap voltage signal is higher than a first preset value or not;
if yes, judging that the processed material is an insulating material;
if not, the processed material is judged to be a conductive material.
Preferably, the method further comprises the following steps:
when the gap is judged to be in a non-short-circuit state according to the gap current signal, judging whether the voltage value of the gap voltage signal is between a second preset value and a third preset value;
if yes, judging that the processed material is an insulating material;
and if the voltage value of the gap voltage signal is lower than the second preset value, the gap voltage signal is judged to be a conductive material.
Based on the pulse power supply and the pulse modulation method, the sampling module is used for collecting gap voltage and gap current signals of the discharge gap, the material which is subjected to discharge machining can be judged, whether current discharge is abnormal or not is judged according to the collected gap voltage and gap current signals, the main control module generates corresponding pulses according to the judgment result and sends the corresponding pulses to the driving amplification module for isolation and amplification, and the discharge main loop outputs the amplified pulse signals to the discharge gap so as to eliminate abnormal power generation signals of materials of all layers in the electric machining process.
Drawings
Fig. 1 is a schematic structural diagram of a pulse power supply according to a first embodiment of the present invention;
fig. 2 is a schematic structural diagram of a main control module according to an embodiment of the present invention;
FIG. 3 is a schematic illustration of material identification provided by an embodiment of the present invention;
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings of the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", and the like, indicate orientations and positional relationships based on those shown in the drawings, and are used only for convenience of description and simplicity of description, and do not indicate or imply that the equipment or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be considered as limiting the present invention.
In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature.
The following detailed description of specific embodiments of the invention refers to the accompanying drawings.
The invention discloses a pulse power supply and a pulse modulation method, and aims to solve the problem that the existing electric spark machining pulse power supply cannot simultaneously meet the requirement of correcting the discharge abnormality of an insulating-conductive multilayer material during machining.
Referring to fig. 1, a first embodiment of the present invention provides a pulse power supply, including: the device comprises a sampling module, a main control module 1, a driving amplification module 2 and a
the sampling module is used for collecting gap voltage and gap current signals of a discharge gap required by material type detection and abnormal discharge state detection;
the main control module 1 is used for receiving machining parameters of the upper computer 6 and gap voltage and gap current signals collected by the sampling module, judging the type of a currently machined material and an abnormal discharge state corresponding to the currently machined material, generating an initial pulse signal according to the machining parameters, modulating the pulse signal according to different material types and the corresponding abnormal discharge states, and outputting the modulated pulse signal through the driving amplification module 2 and the discharge
It should be noted that, in the prior art, when a pulse power supply is used to electrically process insulating and conductive materials, the pulse power supply determines the abnormal discharge state during processing through a detection circuit and a related program, and adjusts the discharge waveform output by the pulse power supply in real time by using a main control program, but the real-time adaptive adjustment and rapid elimination of the abnormal discharge state during the electric spark processing of each layer of material cannot be realized, and the requirements of the surface processing quality of the insulating layer and the base conductive material cannot be met at the same time.
In this embodiment, the real-time processing material sampling module 5 of the sampling module is electrically connected to the I/O port of the main control module 1, and receives the gap voltage and current signals collected by the real-time processing material sampling module to determine the type of the currently processed materials, such as insulating materials and conductive materials, the abnormal discharge real-time sampling module 4 of the sampling module is electrically connected with the I/O port of the main control module 1, and the gap voltage and current signals collected by the sampling module are received to judge the current discharge state, the main control module 1 outputs the modulated pulse signal to the driving amplification module 2 for isolation and amplification treatment (such as driving MOSFET to be rapidly switched on and off) according to the collected processing material and discharge state, the
The abnormal discharge real-time sampling module 4 is used for counting and analyzing abnormal discharge sampling signals based on abnormal discharge waveform characteristics of insulating ceramics and conductive materials, and judging whether gap discharge is abnormal discharge in real time.
In this embodiment, the main control module 1 is an FPGA controller.
It should be noted that, in other embodiments, the main control module 1 may also be another type of controller, which is not specifically limited herein, but these schemes are within the protection scope of the present invention.
Referring to fig. 2, in the present embodiment, the main control module 1 includes a serial port receiving module 14, an abnormal discharge detection and determination module 12, a real-time machining material determination module 11, an abnormal discharge control module 13, and a
the serial port receiving module 14 is used for receiving the processing parameters of the upper computer 6;
the abnormal discharge detection and judgment module 12 is used for receiving the data collected by the abnormal discharge real-time sampling module 4 and generating an abnormal discharge signal;
the processing material real-time distinguishing module 11 is used for receiving the data collected by the processing material real-time sampling module 5 and generating a material type signal;
the abnormal discharge control module 13 is used for receiving the abnormal discharge signal and the material type signal and generating an abnormal discharge control signal;
the
It should be noted that the processing material real-time distinguishing module 11 is configured to analyze the gap voltage and the current collected by the processing material real-time sampling module 5, and output a material type signal to the abnormal discharge control module 13 in real time, the abnormal discharge detection distinguishing module 12 is configured to analyze the gap voltage and the current collected by the abnormal discharge real-time sampling module 4, and output an abnormal discharge signal to the abnormal discharge control module 13 in real time, the abnormal discharge control module 13 outputs an abnormal discharge control signal to the
In this embodiment, the power supply further comprises a power conversion circuit;
the input end of the power conversion circuit is used for connecting an external power supply, and the output end of the power conversion circuit is electrically connected with the power input ends of the sampling module, the main control module 1, the driving amplification module 2 and the discharging
It should be noted that the power conversion circuit is used for connecting an external AC power source, for example, AC220V, and converting the voltage into DC24V for use by each module, and in other embodiments, the power conversion circuit may also be a switching power source for converting AC into DC, which is not limited herein, but these schemes are within the protection scope of the present invention.
A second embodiment of the present invention provides a pulse modulation method, including:
receiving a material type signal and an abnormal discharge signal acquired by a sampling module;
generating an abnormal discharge state control instruction according to the material type signal and the abnormal discharge signal;
and receiving the machining parameters sent by the upper computer 6, and generating a pulse waveform according to the abnormal discharge state control instruction to realize the discharge machining of the material and the removal of the abnormal discharge state.
In a further embodiment, the abnormal discharge state control instruction includes: a cleaning pulse command, a shut-off command, or a hold current machining state command.
It should be noted that the main control module 11 may output different abnormal discharge state control commands according to the currently processed material and the current abnormal condition, for example, when it is detected that the current processing is abnormal, output a command for maintaining the current processing state to continue the processing, and output a cleaning pulse command or a shutdown command to perform modulation when it is detected that the current processing is abnormal.
In a further embodiment, the material type signal includes a conductive material signal and an insulating material signal, and the determining method includes:
acquiring a gap current signal, and judging a gap short circuit state according to the gap current signal;
and acquiring the gap voltage signal, and judging the type of the material according to the gap voltage signal and the gap short circuit state.
In a further embodiment, the obtaining the gap voltage signal and determining the type of the material according to the gap voltage signal and the gap short-circuit state specifically include:
when the gap is judged to be in a short-circuit state according to the gap current signal, judging whether the voltage value of the gap voltage signal is higher than a first preset value or not;
if yes, judging that the processed material is an insulating material;
if not, the processed material is judged to be a conductive material.
Preferably, the method further comprises the following steps:
when the gap is judged to be in a non-short-circuit state according to the gap current signal, judging whether the voltage value of the gap voltage signal is between a second preset value and a third preset value;
if yes, judging that the processed material is an insulating material;
and if the voltage value of the gap voltage signal is lower than the second preset value, the gap voltage signal is judged to be a conductive material.
It should be noted that, referring to fig. 3, a high resistance state exists in the electric spark machining of the insulating ceramic, but almost no conductive material exists, the insulating and conductive materials can be distinguished by detecting whether the discharge waveform is in the high resistance state, and the gap voltage and current collected by the real-time sampling module 5 for the machined material can distinguish the high resistance discharge state from the low resistance discharge state.
Since the high and low resistance discharge states of the short circuit and non-short circuit pulses are easy to be confused, it is necessary to first determine whether the discharge state is a short circuit state, and then further determine whether the discharge state is a high resistance state or a low resistance state. The collected gap current signal can be used for judging whether the gap current signal is in a short-circuit state or not, when the gap current signal is judged to be in the short-circuit state, whether the gap voltage is higher than a first preset value or not is judged, if the gap voltage is higher than the first preset value, the gap voltage is judged to be in a high-resistance state or not is judged to be in a low-resistance state if the gap voltage is lower than the first preset value, when the gap current signal is judged to be in a non-short-circuit state, if the gap voltage is in a third preset value, the gap voltage is judged to be in an open-circuit state, if the gap voltage is between a second preset value and a third preset value, the gap
Based on the pulse power supply and the pulse modulation method, the sampling module is used for collecting gap voltage and gap current signals of a discharge gap, the material which is subjected to discharge machining can be judged, whether current discharge is abnormal or not is judged according to the collected gap voltage and gap current signals, the main control module 1 generates corresponding pulses according to the judgment result and sends the corresponding pulses to the driving amplification module 2 for isolation and amplification, and the discharge
The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention.
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