Electronica ELPULS10 Operation & Maintenance

OPERATING MANUAL FOR

ELPULS 10 ------------------------------------------------------------------------ ------------------------------------------------------------------------ REGD. OFFICE : WORKS : MARKETED BY : ELECTRONICA MACHINE ELECTRONICA MACHINE ELECTRONICA TOOLS LTD. TOOLS LTD., ELEKTRA CHAMBERS, ELEKTRA HOUSE, 691/1 A, SASWAD, 44, MUKUND NAGAR, PUNE SATARA ROAD, TAL. : PURANDHAR PUNE - 411037. PUNE - 411037 (INDIA) DIST. : PUNE - 412301 (INDIA) (INDIA.)

D:01:219:05:11

INDEX Page No.

CHAPTER I INTRODUCTION

EDM PRINCIPLE .....1 - 1 CONCEPT OF 4 AXIS WIRE CUT EDM .....1 - 2

CHAPTER - II PULSE GENERATOR UNIT

GENERATOR FRONT VIEW ..... 2 - 1 GENERATOR REAR VIEW ..... 2 - 2 SAFETY INSTRUCTIONS ..... 2 - 3 NC CONTROLLER FUNCTION KEYS ..... 2 - 5 AUTO MODE (AUT) 2 - 5 DRY RUN (DRY) 2 - 5 SINGLE BLOCK (SB) 2 - 6 LINEAR POSITIONING (LP) 2 - 6 EDGE FINDING (EF) 2 - 8 CENTER FINDING (CF) 2 - 8 FUNCTION (FN) 2 - 9 NCP MODE (NCP) 2 - 9 SERIAL COMMUNICATION 2 - 9 INSTALL 2 - 11 mm / inch MODE 2 - 15 NCPLIST 2 - 16 NCPLOAD 2 - 17 USB 2 - 21 MACHINE CONTROL KEYS ..... 2 - 25 MANUAL JOGGING KEYS ..... 2 - 26 MACHINE CONTROL UNIT ..... 2 - 27 MACHINE CONTROL UNIT & NC CONTROOLER ..... 2 - 28 MDI PROGRAM SCREEN ..... 2 - 31 CUTTING RATE INDICATOR 2 - 34 WIRE VERTICALITY PROCEDURE ..... 2 - 35 MACHINING PROCEDURE ..... 2 - 35 EXAMPLES OF PROGRAMMING IN MDI ..... 2 - 36 STORING OF PROGRAM IN BUFFER ..... 2 - 39 DOs & DONts OF NC CONTROLLER ..... 2 - 40

CHAPTER - III MACHINING START UP PROCEDURE

INTERFACE BUNCHES CONNECTION S 3 - 1 FUNCTIONAL CHECK ..... 3 - 2

PREPARATION OF MACHINING 3 - 3 PROCEDURE FOR MACHINING 3 - 4

CHAPTER - IV MAINTENANCE

SYSTEM CHECK ..... 4 - 1 PERIODICAL MAINTENANCE FOR ..... 4 - 2

POWER SUPPLY UNIT

CHAPTER - V PREJOG 5 - 1

CHAPTER - I

INTRODUCTION

1.1 EDM PRINCIPLE Electric discharge machining (EDM) is a process of repetitive sparking cycles. Graphical representation of sparking cycle is shown below.

t(SVP

TON TOFF

Series of Electrical pulses are applied at the Interelectrode gap.

VP

t(S)

TON TOFF

Td

Interelectrode gap voltage Waveform during sparking is as shown above. t(S)

IP

TON TOFF

t(S)

Interelectrode gap current waveform during sparking is as shown above. Where : TON : Pulse ON period TOFF : Pulse OFF period Td : Spark initiation period (Ignition delay) Vp : Open gap voltage Vg : Average gap voltage Ip : Machining peak current

ELECTRONICA MACHINE TOOLS LTD. Page : 1 - 1

1.2 CONCEPT OF 4-AXIS WIRE CUT EDM The ELEKTRA WIRE CUT Electric Discharge Machine comprises of a Machine Tool, a Power Supply Unit (ELPULS) and a Dielectric Unit. The machine tool comprises of a main worktable (called X-Y table) on which the workpiece is clamped, an auxiliary table (called U-V table) and wire drive mechanism. The main table moves along X and Y axes, in steps of 1 micrometer, by means of X and Y pulse motors, whereas the U-V table moves, in steps of 1 micrometer, by means of U and V pulse motors along U and V axes which are parallel to X and Y axes respectively. A traveling wire which is continuously fed from wire feed spool and collected in bin, moves through the workpiece. It is supported under tension between a pair of wire guides which are located at the opposite sides of the workpiece. The lower wire guide is stationary whereas the upper wire guide which is supported by the U-V table can be displaced along U and V axes, with respect to the lower wire guide. The upper wire guide can also be positioned vertically along Z axis by moving vertically.


The Power Supply Unit (ELPULS) comprises of - 1. U-V controller with U-V axes drive and position display. 2. Main X-Y controller with X and Y position and machining block number display. 3. Machining pulse parameter and servo control unit. 4. X-Y motor driver unit. 5. Machining pulse generator unit. A series of electrical pulses generated by this pulse generator unit are applied between the workpiece and the traveling wire electrode, to cause the electro-erosion of the workpiece material. As the material removal or machining proceeds, the worktable carrying the workpiece is displaced transversely by the X-Y controller and driver along a predetermined path programmed in the controller. The path specifications can be supplied to the controller via a NC program buffer or directly through the controller keyboard (Manual Data Input Mode [MDI] ). When the X-Y table is moving along the predetermined path, if the U-V table is kept stationary, a straight cut with a predetermined pattern is formed. In order to produce taper machining, the wire electrode has to be titled. This is achieved by displacing the upper wire guide (along U-V axes) with respect to the lower wire guide. The desired taper angle is achieved by simultaneous control of the movement of X-Y table and U-V table along their respective predetermined paths stored in the controller. The path information of X-Y table and U-V table is supplied to the controller in terms of linear and circular elements via NC program. While the machining is continued, the machining zone is continuously flushed with water passing through the nozzles on both sides of the workpiece. The part programming system ELAPT : The geometry of the profile and the motion of the wire electrode tool along the profile is fed to the part programming system through keyboard, in terms of various definitions of points, lines and circles as the tool path element, in a totally menu driven, conversational mode. The wire compensation (for wire diameter and machining overcuts) and taper gradient can be specified for the total path or for each path element separately. After the profile is fed to the computer, all the numerical information about the path is calculated automatically and its printout is generated. The entered profile can be verified on the graphic display screen and corrected if necessary. After successful profile definition, the profile is recorded by the computer on floppy, which is then put in the Generator for execution of the program.


CHAPTER - II PULSE GENERATOR UNIT


REAR VIEW



2.1 SAFETY INSTRUCTIONS : 1. Do not open the Panel unless MCB is OFF.

2. Do not touch the Electrode wire during machining (High Voltage) 3. Servicing of the machine must be done by trained personnel only.

Fig.1

Fig.2


2.2 NC CONTROLLER FUNCTION KEYS

2.2.1. AUTO MODE

Select auto mode for machining. This function selects the Sparking mode. Machining can

be carried out in this mode as follows :

1. Press AUTO key. AUTO indicator glows on the screen. 2. Press PROG key. Ref. Fig.6 STBLK (Start block) is highlighted. 3. Enter start Block No. (STBLK), End Block No. (ENBLK) with the help of `NEXT' key. 4. Press `END to come out of the loop. 5. Start machining by pressing `SPARK ON push button, on the power supply unit.

Machining starts from start block no. and stops after it reaches end block. Machining stops if, any of the following condition occurs.

a) `SPARK OFF actuator of power supply unit pressed. b) Stroke end limit switches of NC table operates. c) Wire feed is deselected.

6. Wire breaks. Machining can be started from the same point again by removing the causes.

NOTE : START Block = 1-198 (MDI) END 2-199 1-998, 2-999 00 in MDI mode and 1000 in NCP mode. Similarly, START Block = END Block is also not permissible.

2.2.2. DRY RUN

To execute the program without machining. This function allows the NC table to follow the

path exactly the same way as it is going to cut during machining. The sequence is as follows :

Press DR key. DR indicator glows on the screen. Press PROG key. STBLK (START BLOCK) is highlighted. Ref.Fig.6. Enter Start Block No. Press NEXT key. Highlighter moves to ENBLK (END BLOCK). Enter End Block No. Press END key. To come out of programming mode. X-Y co-ordinate display restores. Press CS key. CYCLE START message is displayed. Table starts moving as per the program in MDI.

Following interlocks disable the DR function.

1. HALT key. 2. Stroke end limit switches. When the function is over Press DR key again to come out of the DR mode.


2.2.3. SINGLE BLOCK

To select a single block operation during dry run or during machining. 2.2.4. LINEAR POSITIONING

To position the worktable at any desired co-ordinates. NC table can be positioned to a desired co-ordinate by using linear positioning function. The sequence of operation is as follows:

a. Press LP key.

b. Screen changes as shown in Fig.3 below

Fig. 3


Following options are available as shown in the figure

i. LP MODE

ii. SERIAL

iii. INSTALL

iv. mm / inch MODE

v. NCPLIST

vi. NCPLOAD

c. Bring the Yellow bar on LP Mode and double click the Select switch. Controller will go in LP mode.

In LP Mode by pressing PROG key X, Y co-ordinates are displayed on the screen as

shown in the Fig. 3 below Fig. 4

You can read or enter new value of X, Y. After entering new value for X press

NEXT key and then enter new Y value. After entering values press END key. Press CS key to move the X-Y table to the newly entered X, Y values. To come out LP Mode press LP key again.


2.2.5. EDGE FINDING

To position the wire electrode at the edge of the workpiece. The function is used to find edge of the job (workpiece) by contact sensing. Wire electrode touches the workpiece and stops. This function is to be executed with appropriate wire feed (i.e. 2 Meters /min.). The sequence is as follows:

d. Press desired direction key (X+, X-, Y+, Y-) NC table moves in selected direction till wire electrode touches workpiece.

e. After the contact is sensed, edge finding function is disabled in that particular direction

only. In all other directions it is still possible to operate the function.

f. The continued process of edge finding can be halted by HALT key and can be started again if required - by direction key.

g. To come out of EF mode, same key (EF) is to be pressed. EF indicator goes off.

2.2.6. CENTRE FINDING

To position the wire electrode at the CENTRE of the hole in the workpiece. This function is used to place the wire electrode exactly at the CENTRE of the cavity. This function is to be carried out with appropriate wire feed (i.e. Meters /min.)..

The sequence of operation is as follows :

h. Press CF key - CF indicator glows. i. Press +X or -X direction key. Table moves along X axis and finds its CENTRE by noting the

co-ordinates at both the edges of the cavity .

j. Press +Y or -Y direction key table moves along Y axis and finds its center by noting the co-ordinates at both the edges of the cavity.

k. After center findings HALT operation is same as in EF function. To come out of CF mode,

press CF key again.


2.2.7 FUNCTION 0-0

2.2.8. NCP MODE KEY

To select NCP mode. Press NCP key. NCP indicator glows , WRINH message is

displayed when this function is selected. WRINH indicates that writing into MDI memory is inhibited. TPR indicator comes on the screen when 4 axes are executed.

This function allows the user to execute programs stored in controller buffer upto 1000 Blocks. NCP file should not exceed more than 1000 Blocks. You can store multiple NCPs up to 1000 Blocks on the same floppy.

2.3 SERIAL COMMUNICATION Select SERIAL from the list of available options in LP mode. After selecting Serial mode, the no. Of available options for the type of serial communication are displayed. (Please refer to Fig. 5). There are two types available

1. SERIAL V 2.0 (3 WIRE NULL MODEM TYPE) 2. SERIAL V 1.0 (CONVENTIONAL SERIAL WITH HANDSHAKING)

NOTE - The Recommended type is option a . (i.e. SERIAL V 2.0 ). Also note that user

will have to select same type of serial communication on the ELAPT / ELCAM side. SERIAL V 2.0 is applicable only for following versions For EMT80W1 VERSION 2.20 & ONWARDS For ELAPT VERSION 3.33 & ONWARDS For ELCAM VERSION 1.10 & ONWARDS


Fig. 5

STORING OF NCP BY USING SERIAL MODE 1. Select type of serial communication (for e.g. serial v 2.0) from both sides,

i.e. from ELAPT / ELCAM side & from M/c side. 2. In dialog box from offline PC, select comport and the baud rate. (For further

discussion on serial from ELAPT / ELCAM side, please refer to the ELCAM / ELAPT operating manual).

3. From M/c side, select SERIAL V 2.0 . After that, the baud rate selection screen will appear as shown in the Fig. 6 below

Fig. 6


4. Select the required baud rate by using SELECT switch from front panel of the generator. Keep same baud rate in offline PC. Same baud rate should be selected from M/c side as well as from offline PC. NOTE The Recommended maximum baud rate for serial communication is 19200.

6. After selecting the baud rate, CONNECTING TO TRANSMITTER is displayed on the screen. Refer to Fig. 7

7. Press ENTER key from offline PC. The required file is transmitted from offline PC to the machine.

Fig. 7

2.4 INSTALL (MACHINE & LANGUAGE INSTALLATION PROCEDURE)

6. By default, there will be English version loaded into the machine. From DIRECTORY ENTRY menu, option of INSTALL is given.


Fig.8 Fig.9


User can install the machine type of his choice from the given list. Following machines are given in the list: -

1. ECOCUT/ OMNICUT 2. MAXICUT/ e 3. 2 AXIS BACK

2 AXIS option: if this option is selected then After rebooting the machine, U and V axes displayed from software is disabled. Only X and Y-axes are displayed in all the modes where axes display is required. NOTE: If 2 AXIS option is selected, then U and V axes are disabled from software. After U and V axes are disabled, 4-axis (Tapered) jobs cannot be cut. So it is recommended that if U and V axes are disabled, then 4-axis profile should not be downloaded into the machine.

Back option:

If Back option is selected, then previous menu of DIRECTORY ENTRY is displayed.

7. After selecting the machine type, the language selection screen is displayed. User can install the language of his choice from the given list.

Fig. 10


Following languages are given in the list: - 6. ENGLISH 7. CHINESE 8. RUSSIAN 9. GERMAN 10. JAPANESE 11. FRENCH

BACK Back option: If Back option is selected, then previous menu of SELECT MACHINE is displayed. 3. After selecting the language, the message Please reboot the machine is Given. After rebooting the machine, the software will appear in selected Language. Fig.11

After language selection is done, the message Please Reboot The Machine is displayed. After rebooting the machine, the selected m/c & selected language will take its effect.


2.5 mm / inch MODE This function selects the mode of display. Available options are

a. mm b. inch Refer to Fig. 12 Fig. 12

After selecting inch mode, all the screen parameters are converted from mm to inch as shown in the figure below NOTE - The default mode of display is mm . Back option: If Back option is selected, then previous menu of DIRECTORY ENTRY is displayed.


Fig. 13

2.6 NCPLIST

When this option is selected, the list of NCP files present in the machine is displayed as shown in the Fig. 14. Fig. 14


Note that these NCP files are already loaded in the machine by the user. To select any of the files, follow the procedure given below

1. To scroll through directory, press SELECT switch once. So the cursor will move down.

2. To select NCP file, press SELECT switch twice. (Double click) 3. After selecting NCP file, then the selected NCP file is downloaded to EPROM as

shown in the fig. 15 Fig. 15

2.7 NCPLOAD (STEPS FOR DOWNLOADING NCP USING FLOPPY DRIVE) -

1. Insert 1.44 MB floppy on which NCP file is stored. 2. Press LP key. Select NCPLOAD option. 3. The list of the available NCP files on floppy are displayed as shown in the Fig. 16 below


Fig.16

4. To scroll through directory, press SELECT switch once. So the cursor will move down.

5. To select NCP file, press SELECT switch twice. (Double click) 6. After selecting NCP file, the controller will check the total number of blocks in

the selected NCP file. And the message Checking no. Of blocks is displayed as shown in Fig. 17

Fig. 17


7. After checking number of blocks, if no. Of blocks exceeds the downloading limitations (2-axis: 999 and 4-axis: 862) then the message Downloading not allowed. Please Break NCP is displayed. The message given for block downloading limitations flashed at this instant. Then the process of NCP downloading is aborted. The cursor will remain as it is as shown in Fig. 18 Fig. 18 8. If the no. Of blocks in NCP file are within the limits, then the program is downloaded in the

controller and block counting will start as shown in the fig. 19 below Fig. 19


9. When block counting stops, press LP switch. Press following sequence of keys: i. Press NCP key. NCP indicator flash on CRT. ii. Press DR key. DR indicator flash on CRT. And the current NCP profile is

displayed on the screen as shown in the fig. 20 below Fig. 20

iii. Press PROG key. STBLK (START BLOCK) is highlighted. Enter Start Block No. Press NEXT key. Highlighter moves to ENBLK (END BLOCK). Enter End Block No. Press END key to come out from programming mode. iv. After coming out from program screen, X-Y coordinate display restores. Press CS key. Table starts moving as per the program downloaded in controller.


2.8 USB

Select USB from the list of available options in LP mode. After selecting USB mode, Baud Rate displayed Select the baud rate according to CPU. After that RECIVE option displayed. (Please refer to Fig. 21). Fig. 21 After selecting RECIVE mode, PROG option displayed. (Please refer to Fig. 22). Fig 22


After Selecting PROG mode, List of the NCP files from the USB is displayed. (Please refer Fig 23) Fig 23 Select the NCP file which you want to receive. After selecting the file it will display the message Receiving Filename.ncp (Please refer Fig 24) Fig 24


After completion it will display the message Program d:\Filename.ncp Received Press any Key. (Please refer Fig 25). Now you can use that NCP file. Fig 25

Messages Displayed:

1. "File copied successfully..Press Any Key" This message is displayed when file has been successfully transferred. 2. "No USB Device...Press Any Key" This message is displayed when there is no USB disk inserted in the USB port. Please insert the USB disk and try again. 3. "Communication Error (Press USB Reset Key)..Press Any Key" This message is displayed when command failed to execute. Please retry the action or reset the USB Communication interface. 4. "File not foundPress Any Key" This message is displayed when the file to be Transferred is not present in the USB disk. 5. "USB Device FullPress Any Key". This message is displayed when the USB disk is full. 6. "Read only FilePress Any Key". This message is displayed when read only file is being modified



7. "No Response from USB! (Press USB Reset Key)Press Any Key". This message is displayed when USB serial communication interface is not responding. 8. "Error While Opening FilePress Any Key". This message is displayed when file is already open and new file is being opened. 9. "Filename InvalidPress Any Key". This message is displayed when file name contains disallowed characters. 10. "Directory Not EmptyPress Any Key". This message is displayed when

directory being deleted is not empty. 2. 9 MACHINE CONTROL KEYS

2.9.1 POWER ON INDICATION

This LED indicates the presence of 3 PH supply in the generator. 2.9.2 MACHINE LOCK INDICATION

This LED glows when machine lock switch is pressed. 2.9.3 FEED HOLD

This LED glows when gap short condition remains for more than 4 min. 2.9.4 X DISPLAY RESET SWITCH

X axis display is reset to 0 by this switch. It works only when operation is in manual mode. 2.9.5 Y DISPLAY RESET SWITCH

Y axis display is reset to 0 by this switch. It works only when operation is in manual mode. 2.9.6 U DISPLAY RESET SWITCH

U axis display is reset to 0 by this switch. It works only when operation is in manual mode.


2.9.7 V DISPLAY RESET SWITCH

V axis display is reset to 0 by this switch. It works only when operation is in manual mode. 2.10 MANUAL JOGGING KEYS 2.10.1 MANUAL JOG For positioning the work table in manual mode. Low jog pot on MCP and jog feed pot on MJ-1 Keyboard allows the speed variation in manual jogging. 2.10.2 UV JOGGING KEYS

These keys are provided to move the U-V table in Manual mode. Jogging speed can be

changed with the help of jog feed pot on MJ-1 Keyboard. 2.10.3. SPEED HI

Pressing this key, selects high speed for jogging. Pressing the same key again, selects low

speed. At the same time controller will display HI, LO status on the screen. 2.10.4. X JOG & Y JOG KEYS

Operating any one of these 4 keys in `Manual Mode moves the NC table in X and Y direction.


The arrows indicate directional movement of the wire. Pressing of a key and immediate release of the same execute an incremental jogging of 1 micron & table moves by 1 micron. By pressing a key for more than 1 Sec.(Approx.) executes continuous jogging on NC table.Only 1 key is recognised at a time. Table movement stops when it crosses a limit of that axis. Limit switches for each axis viz. +X,-X, +Y,-Y are mechanically fixed at the stroke end. When any one of the four limit switches are operated. Limit indication comes on the screen. 2.10.5. HOME (ORIGIN) Pressing this key in manual mode, table comes to origin. This means table goes back to

(0.0) from its initial reading through the shortest path. During this returning period `HOME message will be displayed on the screen.

2.10.6. EMERGENCY OFF SWITCH

This switch when pressed 3 Ph power supply to the Generator is switched OFF. It is to be

used in case of emergency. 2.10.7. SELECT SWITCH

Pressing Select switch will bring the cursor at its required position in following condition.

- Programming is halted during execution of first block and it is required to start again. In this condition press RST key then press Select switch. This switch is also used to select and load the program from 1.44 MB floppy to controller memory and to select the LP mode.

2.11 MACHINE CONTROL UNIT 2.11.1. MACHINING GAP VOLTAGE METER

This meter indicates average machining gap voltage.


2.11.2. MACHINING CURRENT METER

Average machining current from 0 to 10A is indicated by this meter. 2.11.3. POWER ON (DAY / NIGHT)

The system is switched ON by turning this switch to day position. In Sparking mode, if the

switch is placed in Night mode after completion of machining the Machine will be switched OFF.

2.11.4. POWER OFF This switch cut off 3 Phase supply to the generator. 2.12 MACHINE CONTROL UNIT AND NC CONTROLLER This unit controls the machining parameters like gap, sensitivity ON time, OFF time,

current etc. All these parameters can be set to desired values. The unit also provides functions and indications like buzzer, gap voltage and gap current, time totalizer and machine locking etc. The details of the functions are as follows.

2.12.1 SPARK ON SWITCH

This is a Green top push button type switch. Sparking across the gap starts when this is

pressed .


2.12.2 SPARK OFF SWITCH

This is a White top push button type switch, to use to stop the sparking. 2.12.3 BUZZER

Buzzer sounds for 30 sec. when the wire breaks, or when the sparking program is over. 2.12.4 BUZZER / FEEDHOLD RESET SWITCH

A push button type switch to be pressed to stop the buzzer, when machine trips during

sparking and WF, FL selection is not possible and to reset the Feed Hold indication. 2.12.5 PULSE ON TIME SETTING KNOB

ON time can be set in 10 steps (from 1 to 10). Larger number indicates higher ON time,

which allows greater current, as well as higher duty factor. 2.12.6 PULSE OFF TIME SETTING KNOB

OFF time can be set in 10 steps (from 1 to 10). Larger number indicates higher time, which allows reduced current, as well as lower duty factor.


2.12.7 PULSE OFF TIME SETTING KNOB

TOFF1 position 1,2,3 should be used only in SKIM cut mode. 1 will have lower TOFF, 3 will have higher TOFF. TOFF1 position 4,5,6 should be used only in rough cut mode. 4 will have lower TOFF, 6 will have higher TOFF. 2.12.8 GAP SET KNOB

This pot can set sparking gap. Larger number indicates the higher gap. 2.12.9 SENSITIVITY ADJUSTMENT KNOB

Feed or sensitivity adjustments of servo can be made with this knob. Larger knob number

indicates higher machining speed. 2. 12.10 CONSTANT / PROPORTIONAL MODE

This facilitates constant table feed rate for accurate job profile. LEFT position for Proportional mode and RIGHT position for Constant mode.


2.12.11 LINEAR / CIRCULAR

To select Linear or Circular interpolation in a block. 2.12.12 M/C LOCK SWITCH

Coordinate table can be locked by this switch. When this switch is pressed and if program is

running, display will keep on changing but table will not move. Fig.26


Fig. 27 2.12.13 CLOCKWISE/ COUNTERCLOCK WISE

To select the direction of circular interpolation. 2.12.14 NUMERICAL KEYS

To enter all numerical parameters while programming.


2.12.15 PROGRAM KEY

To select programming mode. 2.12.16 INSERT KEY

To insert a new block in between the two blocks. 2.12.17 CLEAR

To clear the entered values. 2.12.18 END KEY

To come out of programming mode. 2.12.19 NEXT KEY

To select next parameter for data entry. 2.12.20 RESTART

To restart NCP before starting a new job. 2.12.21 CYCLE START

To start the function of dry run on linear positioning.



.12.22 HALT

2

To stop the function of dry run linear positioning, EF, CF, HOME.

.12.23 TIME TOTALIZER

2

This records only the machining hours of the machine. This cannot be reset to zero.

2.13 CUTTING RATE INDICATOR

The cutting rate indicator provided on the controller, indicates the feed rate of the main (X-Y) ble in

etting of cutting parameters, during taper cut, with reference to the cutting rate indicator may result

(Generator back side).

ta mm/minute. During a straight cut, it directly shows the cutting rate in mm/minute. However, during a taper cut, when both the main (X-Y) table and auxiliary (U-V) table are traveling, the actual cutting rate which is the effect of the movement of X-Y table and U-V table, is higher than the feed rate of main (X-Y) table, which is indicated by the cutting rate indicator. Hence, the actual cutting rate during taper cut is higher than that displayed by the cutting rate indicator. Therefore, during taper cut, the cutting parameters should be set as per the parameters selected during the test cut and not with reference to the cutting rate indicator. Sin unstable machine operation and frequent wire breakage as the actual cutting rate will be higher than the cutting rate shown by the indicator.


2.14 WIRE VERTICALITY PROCEDURE (USING VERTICALITY BLOCK)

1. Mount the Wire verticality block on the Job stand and make X-Z and Y-Z face true to Quill movement.

2. A. Thread the wire & select following conditions. Wire feed :2 m/min. B. Select EF function and give motion in X negative direction. C. Check the spark is moving from top to bottom of Wire verticality block.

D. If spark is not moving from top to bottom, make the displacement of U axis as per the requirement. Take wire to X positive direction and repeat 2B, and achieve the spark movement for full surface.

E. Make U display 0.000 F. Repeat the 2B, 2C and 2D for Y-Z plane and adjust the V axis. G. Make V display 0.000

MANUAL MODE :

This mode is selectable from the NC Controller Rack. If this mode is selected, then the U-V table can be moved by MANUAL JOG keys provided on front panel. Respective limit switch messages are displayed on the screen. The motion is disabled when stroke end limit switch gets actuated.

AUTO MODE :

This mode is selectable from the Control Panel . When Auto or Dry Run is selected, U-V table cannot be moved by MAN JOG keys.

2.15 MACHINING PROCEDURE

1. It is possible to execute 4-axes programs through NCP only. 2. After clamping the job, always DRY RUN is to be carried out. To ensure further, one

may carryout DRY RUN with single block and can check display readings as per the printout taken from the programming system.

3. Before actual cutting, align the wire vertical. 4. Make sure that the quill position (Z-axis) is correctly adjusted, according to

programmed Z position. 5. Select AUTO mode, select W.F., flushing. Make `SPARK ON and adjust the

machining parameters. 6. If quill position is disturbed to remove gap short or for any other condition, please

ensure to bring it at its original position before resuming sparking.

2.16 EXAMPLE OF PROGRAMMING IN MDI (MANUAL DATA INPUT) There is no special code for programming. User has to enter X-Y co-ordinates in incremental mode along with the type of interpolation. Example - 1

Above figure consists of 4 blocks. S.P. designates start point of machining. Co-ordinates

shown are in incremental mode. Arrows indicate direction of machining. The sequence of operation is as follows :

BLOCK NO.1 (BN) -------------------------------------------------------------------------------------------------------------

Sr.No. Press On the Screen Enter

------------------------------------------------------------------------------------------------------------- 1. PROG key BN highlighted at the bottom of 01 through screen. Block No.displayed 000. Numerical key pad 2. NEXT XE highlighted at the bottom of 000.000 screen.(End point in X direction) 3. NEXT YE highlighted at the bottom of 005.000 screen. (End point in Y direction) 4. NEXT M highlighted at the bottom of Select `L screen. L message comes i.e. linear mode. 5. NEXT BN highlighted at the bottom of 02 screen. -------------------------------------------------------------------------------------------------------------

BLOCK NO.2

To be entered in continuation. The sequence is similar to above. XE : 005.000 YE : 000.000 M : L BN : 03


BLOCK NO.3 XE : 000.000 YE : -005.000 M : L BN : 04

BLOCK NO.4 XE : -005.000 YE : 000.000 M : L Press `NEXT key again BN highlighted at the bottom of screen. To come out of this mode, press `END key X-Y co-ordinate display restores. Example - 2

-------------------------------------------------------------------------------------------------------------

BLOCK NO. X-Y CO-ORD. OF END POINT MODE OF INTERPOLATION

------------------------------------------------------------------------------------------------------------- BN XE YE M

------------------------------------------------------------------------------------------------------------- 1 030.000 025.000 L 2 020.000 010.000 L 3 030.000 -025.000 L 4 -80.000 000.000 L -------------------------------------------------------------------------------------------------------------


Example - 3

This consists of circular interpolation at Block No.2 & 4. Co-ordinates of centre of circle (I,J) are shown in incremental mode.

------------------------------------------------------------------------------------------------------------------ Block X-Y co-ordinate Mode of Co-ordinate of Direction No. of End point Interpolation centre of a circle of Circular

Interpolation

------------------------------------------------------------------------------------------------------------------ BN XE YE M I J DN

------------------------------------------------------------------------------------------------------------------ 1 20.000 000.000 L - - - 2 20.000 000.000 C 010.000 000.000 C 3 20.000 000.000 L - - 4 20.000 000.000 C 010.000 000.000 CC 5 20.000 000.000 L - - - 6 000.000 -015.000 L - - - 7 -100.000 000.000 L - - - 8 000.000 015.000 L - - - ------------------------------------------------------------------------------------------------------------------

L = Linear C = Clockwise

C = Circular CC = Counterclockwise



2.17 STORING OF PROGRAM IN BUFFER

The program entered in `MDI mode can be stored on cassette as follows : Press `DR/AUTO - `DR/AUTO indicator on screen glows. Press `PROG key - STBLK is highlighted.

- Enter start Block No.

Press `NEXT key - `ENBLK is highlighted. - Enter End Block No.

Press `NEXT key - `DEST(Destination Block No in cassette) message on display.

Enter destination block No. Press `END key - To come out of programming mode. Press `DR/AUTO - `DR/AUTO indicator goes off. Press `FN followed - The program in MDI mode gets stored by `9 in buffer. Block No. display (N) shows current Block No. being stored in buffer.

The stored program can be verified by selecting `NCP mode. The sequence

of reading the program is same as in MDI mode. CAUTION : If the buffer is re-programmed, previous data gets erased automatically during new program downloading.


2.18 DOs & DONTs for NC CONTROLLER

1. DO NOT press RST key till the end of the program. 2. DO NOT start cutting any profile directly unless dry run of the entire profile is checked

and confirmed. 3. During machining, DO NOT move the table manually till the end of current program OR till

machine end block is executed. 4. ERROR 1 : Message is displayed - Can be clear by pressing CLR key in following

conditions.

A : If RST key is not pressed, before DR/SPK ON. B : If program execution is through MDI, and program is checked OR edited during DR/SPK ON execution.

Note : If program execution is halted during the operation when DR/SPK is `ON say at current block no.4, and if now the manual mode is selected say for checking OR editing of the program then press the switch `PROG before restarting DR/SPK ON. The display will show the block number. Make it 4 + 1 = 5 i.e. one more than the current execution block number.

5. Error 2 : Message is displayed if error comes during programming of buffer in MDI mode. Error can be due to following reasons :

a. Buffer is having less capacity than total number of blocks to be transferred at given

destination block number. b. Buffer is defective.

6. When power fails during cutting of 4 axes job, X-Y & U-V Co-ordinates are stored. When power resumes the sparking can be started from the same point. X-Y & U-V table movement will continue as per the program.

7. While cutting a multi cavity 4 axes job, at the end of each cavity, the U-V display may not

show 0-0. It should be brought back to 0-0 manually by moving the U-V table before starting machining of next cavity.

8. While cutting a 4 axes cavity, at the end of the cavity the U-V display may show a deviation upto 10 microns depending upon the profile & taper.

9. Before starting any fresh job, the wire MUST be made vertical by following `Wire Aligning Procedure.

CHAPTER - III

MACHINING START UP PROCEDURE

3.1 INTERFACE BUNCHES CONNECTIONS:

Place the Machine, Dielectric unit (DU) and Power Supply Unit (PSU) as per floor plan.

Ensure that all wires are in good condition. Check lables as shown in the table below:

SR. NO.

CABLE NO. REMARKS

1.

C04, DS1, DS2, DS3, DS4, DS5, PM1

RACK 0

2.

C12, DS10, DS12, PM1

RACK 1

3.

DS6, DS20, DS23, DS24, DS25 DS26, FC1, JR25, PM1, PM2, PM3

RACK 2

4.

DS34, DC35, C42, TS30

RACK 3

5

C43, TS50

RACK 4 & RACK 5

6.

C60, C60A, C61, C62, C63, C65, C66, C67, TS60, TS1, PM1, PM2

RACK 6

7.

FC1, FC2, FC3, FC4, DS1, PM1 RM1, RM7

BAZEL

= FOR EXPORT ONLY

ELECTRONICA MACHINE TOOLS LTD PAGE : 3 - 1

3.2 FUNCTIONAL CHECK:

Before powering up the NC WIRE CUT EDM user is requested to read this instruction manual carefully.

Check that all cables are connected at their proper positions. Voltage stabliser is must for this machine. Check output voltage of the stabiliser as per specifications.

Before Power ON

- Press machine lock switch. - Keep T ON knob at position 1. - Keep T OFF knob at position 10. - Keep servo sensitivity knob at position 1. - Keep machining gap voltage setting knob at Pos.10

- Keep wire tension knob at position 1. - Keep wire feed knob at position 1. - Keep CCU switch in AUTO mode (Conductivity control unit)

After Power ON - Power ON indicator glows. - Display may show some reading, let it be anything. - Machine lock indicator glows. - Wire feed and wires tension display is in OFF condition. - Gap voltage meter shows Nil voltage - Gap current meter shows Nil current. - All status indicators on screen are in OFF condition. - Conductivity of dielectric fluid is shown on its meter.

After these observations are over, Press FN key. FN indicator glows. Then press a key 0 twice. Screen will go blank except decimal points. This condition remains for about 1 second and then the screen will show X = 00.


Check the following

- Dielectric pump operation. - Select wire feed function and vary the speed of traveling wire. - Jogging in X, Y direction with speed HI and LO. - Select MAN mode of CCU and see that the pump is getting ON, Put it back to AUTO. - Check deionizer by pressing the knob. Meter reading will decrease towards zero. It may not reach up to zero.

3.3 PREPARATION FOR MACHINING

1] Selection of wire Use Brass wire specified by M/s. Electronica, Pune, India. It must be free from any

twists, corrosion and kinks, any of these defects may lead to wire breakage or unstable machining.

2] Wire threading Wire treading is to be done as per the procedure given below a] Mount the wire reel on its shaft so as to unspool the wire. Tighten the nut firmly in a clock wise rotation on to the reel. b] Thread the wire.

c] Wire must be held by the wire breakage detection switch. If this is not

actuated by the wire, the flush, wire feed, wire tension and machining switch will not function.

d] The wire should pass through the groove centres of the wire guides.

Confirm that the wire is positioned at the centre of the dielectric fluid flushing port in order to get the wire surrounding completely by the water column.

e] The wire must remain in contact with the nylon roller at all times so that it is

insulated from the machine tool. f] Do not touch the wire or any part of the wire feed mechanism, during

machining since all are electrically live. 3] Wire tension and wire feed rate

The wire tension is to be adjusted according to the workpiece thickness and size of wire used. Proper tension is set by reading the Wire tension meter on the control box on the machine tool. The wire feed is to be adjusted on the basis of thickness of the job and energy settings.


4] Workpiece mounting The worktable can handle workpiece of maximum size of 400 (L) mm x 500 (W) mm

x 100 (D) mm and maximum weight of 170 kgs. Heavier workpiece may affect the accuracies, and load the coordinate table. (Before mounting the job, grease the mounting surface of tables). The job should be clamped firmly on the jobstands to ensure proper electrical contact.

5] Wire positioning method Wire can be positioned with respect to edge of the workpiece by the function EF.

OR It can be placed at the centre of the pre-drilling hole by the function CF.

OR It can be positioned at machining start point with respect to any known reference point.

3.4 PROCEDURE FOR MACHINING

After the preparation for machining is over, set the flushing and machining parameters. For the programming of the desired profile.

A] Machining parameters to be set are as follows;

1. Pulse ON time - (T ON) 2. Pulse OFF time - (T OFF) 3. Pulse peak current (Ip) 4. Machining gap voltage (Vgp) 5. Servo sensitivity 6. Capacitor - (C1 to C4)

B] Dielectric fluid flushing parameters

Confirm that conductivity of the dielectric fluid is within the specified range. Press the flush switch on the MCP. Adjust dielectric fluid flow valve by watching the flushing pressure fluid flowing from the upper and lower flush ports. The flushing pressure should be approx. 12 kg/sq. cm.


C] Servo parameters Make servo adjustment as follows:

1. Select AUTO mode from Elecon 2 A. Confirm that start block number and end block number are correct.

2. Start machining by SPARK ON switch. 3. Gradually rotate sensitivity knob from position 1.

in clockwise direction and rotate gap voltage knob in anticlockwise

direction. Gap voltage knob enables to set machining speed. Try to keep sensitivity knob towards position 10 to have stable and efficient machining. However, it may not be always possible to keep this knob at position 10.

For trim cutting, following settings should be used :

- Trim cut selector in TRIM position (right side) - Gap capacitors = 1 No. Only - T ON = 1 to 3 position - T OFF = 1 or 2 - IP = Start with position 1 and increase as per requirements during machining - Gap Pot = Extreme anticlockwise position - Sensitivity Pot = Extreme anticlockwise position - Upper flushing = 0.5 to 2 kg/cm. Sq. - Lower flushing = 0 to 0.5 kg/cm. Sq. - Z position = 5 to 10 mm higher than job. - Wire tension 800 to 1200 gms.

During trim cutting, increase the sensitivity potentiometer to

achieve gap voltage between 50 to 70 V.

The cutting speed during trim cut should be 2 to 3 times that in normal cutting for the given job. It should be achieved by adjusting IP or T ON or Sensitivity pot.

4. Now the machine tool coordinate table will have a control signals from RACK I. If power fails

during machining, the machining can be continued from the same point, after power supply resumes; without loosing X-Y display coordinates.


CHAPTER - IV

MAINTENANCE

4.1 SYSTEM CHECK :

ECOCUT WIRECUT ELECTRIC DISCHARGE MACHINE is a precision machine and preventive maintenance of the machine will give long trouble free operation. Improper maintenance will slowly deteriorate the performance achievable from the machine.

SR. NO.

CHECK-UP CHECK-UP PERIOD

REMARKS

1.

EL10 VGA Power Supply Unit a. Input power supply (i.e. 3 Phase output of stabiliser)

Daily

If voltage vary frequently.Get the INPUT power conditions corrected

b. Panel cooling Weekly Machine should not be run for a long period when fans in the panel are not working.

c. Fuses - glass cartridge Weekly Press or tighten if loose.

2. ELCUT MACHINE TOOL a. Wire Drive Mechanism

- Pressure Roller Surface - Lower energising roller

Daily Wirefeed should be smooth.

b. Wire guide & flushing Assly. 100 M/c Hr. Wire should go smoothly. Clean.

c. E & W connections 100 M/c Hr. Tighten properly if loose. d. U-V Table Weekly Move the table by using Man

Jogging function avoid jamming movement of the tables.

e. Flushing hoses for upper and lower wire guide assembly.

To be changed after every 6 months.

Change

3. DIELECTRIC SYSTEM a. Clean the complete system

and hoses also. 150 M/c Hr.

EDM dust settles at the bottom of the system.

b. Changing of water 50 M/c Hr. Clean the system properly. c. Change the paper cartridge

filter (10 micron), in series with filter pump.

50 M/c Hr.

4. Filter cleaning

Twice in a Week

5. PART PROGRAMMING SYSTEM

a. Single phase stabiliser voltage output.

Daily Set the required value.

b. Computer unit cooling fan c. Floppy drive reading head Monthly Clean the drive by using head

cleaning floppy (Standard floppy available in the market).


4.2 PERIODICAL MAINTENANCE FOR POWER SUPPLY UNIT

A regular routine maintenance enhances the MTBF (Mean time between failure) of the machine.

INSPECTION OF POWER SUPPLY :

Checking of fuses and indicators may be attributed to blowing of fuses. Check to find out the cause. Blowing of fuses is indicated by respective LED indicators.

SR. NO.

LOCATION FUSE NO.

RATING FUSE TYPE USED FOR

1. F5 (EV-08M) 750 mA S.B. 20 MM GLASS -5V REGULATOR

2. F6 (EV-08M) 750mA S.B 20 MM GLASS +12V REGULATOR

3. F7 (EV-08M) 750 mA S.B 20 MM GLASS -12V REGULATOR

4. F4 (EV-08M) 750 mA S.B. 20 MM GLASS +5V REGULATOR

5. F1 (EV-08M) 1.5 Amp. F.B. 20 mm GLASS + 24 V FOR WIRE FEED

6. F2 (EV-08M) 3 Amp. S.B. 20 MM GLASS + 24 V FOR RELAY SUPPLY

7. F3 (EV-08M) 250 mA F.B. 20 MM GLASS + 24 V FOR EF/CF FUNCTION

8. F1 EVTR-01 500 sA S.B. 20 MM GLASS S.M.D. CONTROL

9. F2 EVTR-01 500 mA S.B. 20 MM GLASS S.M.D. CONTROL



12. EVTR-02 4A F.B. 20 MM GLASS HT. SMD


CHAPTER V

MP-E1 RCU (Remote Control Unit)

A

5.0

ELEKTRA MP-E1

123

45 6

789

10

LO JOG1

23

45 6

789

10

HI

X- HOME

MP-E1


For positioning the worktable in Manual mode Low jog pot on RCU allows the speed variation in Manual jogging.

SPEED HI

Pressing this key, selects Speed HI for jogging. Pressing the same key again, selects Speed LO. At the same time Controller will display HI, LO status on the screen.

JOGGING KEYS

Operating any one of these 4 keys in `Manual Mode moves the NC table in respective direction. The arrows indicate directional movement of the wire. Pressing of a key and Immediate release of the same Execute an incremental jogging of 1 micron & table moves by 1 micron. By pressing a key for more than 1 Sec. (Approx.) executes continuous jogging of NC table. Only 1 key is Recognized at a time. Table Movement stops when it cross a limit of that axis. Limit switches for each axis viz. +X, -X, +Y, -Y are Mechanically fixed at the stroke end. When any one of the four limit switches is operated, X, Y LIMIT message comes on the screen.

Pressing this key in manual mode, table comes to origin. It means table goes back to (0.0) from its existing position through the shortest path. During this returning period `HOME message will be displayed on the screen.

HALT

To stop the motion of NC table in dry run, linear positioning, EF, CF, HOME functions.

PREJOG

Prejog function works only in auto mode to move worktable after wire breaks press this key and move the table by using jog keys. By pressing same key again table will retain its Original position. During Prejog M/C display reading will not change. LED indication on Prejog key is a NOT IN POSITION indication. It will glow if Prejog is Selected or if Table is not in position after performing this function. Axis movement during position retaining process (After wire threading), can be stopped by pressing this key. Note: For X Axis Prejog press this key twice to return to its original position.


WF

To Start wire feeds press this switch. This is a feed rate at which the fresh wire is fed continuously for sparking. Range: 01 - 10

FLUSH

To Start dielectrics press this switch.

ELPULS 10 OPERATING MANUALINDEXINTRODUCTIONPULSE GENERATOR UNITMACHINING START UP PROCEDUREMAINTENANCEPREJOG

Electronica ELPULS10 Operation & Maintenance

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