FOR
ELPULS 10
------------------------------------------------------------------------
-----------------------------------------------------------------------REGD. OFFICE :
WORKS :
MARKETED BY :
ELECTRONICA MACHINE
TOOLS LTD.
ELEKTRA HOUSE, 691/1 A,
PUNE SATARA ROAD,
PUNE - 411037 (INDIA)
ELECTRONICA MACHINE
TOOLS LTD.,
SASWAD,
TAL. : PURANDHAR
DIST. : PUNE - 412301 (INDIA)
ELECTRONICA
ELEKTRA CHAMBERS,
44, MUKUND NAGAR,
PUNE - 411037.
(INDIA.)
D:01:219:05:11
INDEX
Page No.
CHAPTER I
INTRODUCTION
EDM PRINCIPLE
CONCEPT OF 4 AXIS WIRE CUT EDM
CHAPTER - II
CHAPTER - III
2-8
2-9
2-9
2-9
2 - 11
2 - 15
2 - 16
2 - 17
2 - 21
..... 2 - 25
..... 2 - 26
..... 2 - 27
..... 2 - 28
..... 2 - 31
2 - 34
..... 2 - 35
..... 2 - 35
..... 2 - 36
..... 2 - 39
..... 2 - 40
3-1
..... 3 - 2
3-3
3-4
MAINTENANCE
SYSTEM CHECK
PERIODICAL MAINTENANCE FOR
POWER SUPPLY UNIT
CHAPTER - V
..... 2 - 1
..... 2 - 2
..... 2 - 3
..... 2 - 5
2-5
2-5
2-6
2-6
2-8
CHAPTER - IV
.....1 - 1
.....1 - 2
PREJOG
..... 4 - 1
..... 4 - 2
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.
TON
TOFF
VP
t(S
TON
Td
VP
t(S)
t(S)
TON
TOFF
IP
t(S)
TON
TOFF
Td
Vp
Vg
Ip
:
:
:
:
:
:
Pulse ON period
Pulse OFF period
Spark initiation period (Ignition delay)
Open gap voltage
Average gap voltage
Machining peak current
Page : 1 - 1
1.2
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.
Page : 1 - 2
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.
Page : 1 - 3
CHAPTER - II
PULSE GENERATOR UNIT
Page : 2 - 1
REAR VIEW
Page : 2 - 2
Page : 2 - 3
Fig.1
Fig.2
Page : 2 - 4
Select auto mode for machining. This function selects the Sparking mode. Machining can
be carried out in this mode as follows :
1.
2.
3.
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.
Page : 2 - 5
Page : 2 - 6
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.
Page : 2 - 7
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.
g.
To come out of EF mode, same key (EF) is to be pressed. EF indicator goes off.
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.
Page : 2 - 8
2.2.7
FUNCTION 0-0
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
Page : 2 - 9
Fig. 5
Page : 2 - 10
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
machine.
Fig. 7
Page : 2 - 11
Fig.8
Fig.9
Page : 2 - 12
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
Page : 2 - 13
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.
Page : 2 - 14
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.
Page : 2 - 15
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
Page : 2 - 16
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
Page : 2 - 17
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
Page : 2 - 18
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
Page : 2 - 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.
Page : 2 - 20
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
Page : 2 - 21
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
Page : 2 - 22
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".
file is being modified
ELECTRONICA MACHINE TOOLS LTD.
Page : 2 - 23
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.
Page : 2 - 24
2.9.1
POWER ON INDICATION
FEED HOLD
This LED glows when gap short condition remains for more than 4 min.
2.9.4
Y axis display is reset to 0 by this switch. It works only when operation is in manual mode.
2.9.6
U axis display is reset to 0 by this switch. It works only when operation is in manual mode.
Page : 2 - 25
2.9.7
V axis display is reset to 0 by this switch. It works only when operation is in manual
mode.
2.10
pot
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.
ELECTRONICA MACHINE TOOLS LTD.
Page : 2 - 26
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.
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
2.11.1.
Page : 2 - 27
2.11.2.
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
This is a Green top push button type switch. Sparking across the gap starts when this is
pressed .
Page : 2 - 28
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.
Page : 2 - 29
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.
ELECTRONICA MACHINE TOOLS LTD.
Page : 2 - 30
2.12.11
LINEAR / CIRCULAR
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
Page : 2 - 31
Fig. 27
2.12.13
NUMERICAL KEYS
Page : 2 - 32
2.12.15
PROGRAM KEY
INSERT KEY
CLEAR
END KEY
NEXT KEY
RESTART
CYCLE START
Page : 2 - 33
2.12.22
HALT
To stop the function of dry run linear positioning, EF, CF, HOME.
2.12.23
TIME TOTALIZER
This records only the machining hours of the machine. This cannot be reset to
zero.
Setting of cutting parameters, during taper cut, with reference to the cutting rate indicator may result
in unstable machine operation and frequent wire breakage as the actual cutting rate will be higher
than the cutting rate shown by the indicator.
Page : 2 - 34
2.14
Mount the Wire verticality block on the Job stand and make X-Z and Y-Z face true to
Quill movement.
2. A.
B.
C.
D.
Thread the wire & select following conditions. Wire feed :2 m/min.
Select EF function and give motion in X negative direction.
Check the spark is moving from top to bottom of Wire verticality block.
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
(Z-axis)
is
correctly
adjusted, according to
the
Page : 2 - 35
2.16
X-Y co-ordinates in
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
01 through
Numerical
key pad
2.
NEXT
3.
NEXT
4.
NEXT
Select `L
i.e. linear mode.
5.
NEXT
02
-------------------------------------------------------------------------------------------------------------
BLOCK NO.2
To be entered in continuation. The sequence is similar to above.
XE
YE
M
BN
:
:
:
:
005.000
000.000
L
03
Page : 2 - 36
BLOCK NO.3
XE
YE
M
BN
:
:
:
:
000.000
-005.000
L
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.
MODE OF INTERPOLATION
------------------------------------------------------------------------------------------------------------BN
XE
YE
------------------------------------------------------------------------------------------------------------1
030.000
025.000
L
2
020.000
010.000
030.000
-025.000
4
-80.000
000.000
L
-------------------------------------------------------------------------------------------------------------
Page : 2 - 37
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
No.
X-Y co-ordinate
of End point
Mode of
Interpolation
Co-ordinate of
centre of a circle
Direction
of Circular
Interpolation
-----------------------------------------------------------------------------------------------------------------BN
XE
YE
DN
-----------------------------------------------------------------------------------------------------------------1
20.000
000.000
20.000
000.000
010.000
20.000
000.000
20.000
000.000
20.000
000.000
000.000
-015.000
-100.000
000.000
000.000
015.000
000.000
010.000
000.000
CC
-----------------------------------------------------------------------------------------------------------------L = Linear
C = Clockwise
C = Circular
CC = Counterclockwise
Page : 2 - 38
- STBLK is highlighted.
- Enter start Block No.
- `ENBLK is highlighted.
- Enter End Block No.
- `DEST(Destination Block No in
cassette) message on display.
Enter destination block No.
Press `DR/AUTO
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.
Page : 2 - 39
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 :
conditions.
Message is displayed -
power resumes the sparking can be started from the same point.
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.
Page : 2 - 40
CHAPTER - III
MACHINING START UP PROCEDURE
3.1
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.
RACK 0
2.
RACK 1
3.
RACK 2
4.
RACK 3
C43, TS50
RACK 4 &
RACK 5
6.
RACK 6
7.
BAZEL
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.
After Power ON
- Power ON indicator glows.
Page : 3 - 2
- 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.
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
3]
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]
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.
PAGE : 3 - 3
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]
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
After the preparation for machining is over, set the flushing and machining parameters. For the
programming of the desired profile.
A]
B]
2.
3.
4.
5.
Servo sensitivity
6.
Page : 3 - 4
C]
Servo parameters
Make servo adjustment as follows:
1.
2.
3.
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.
PAGE : 3 - 5
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.
1.
2.
3.
4.
5.
CHECK-UP
EL10 VGA Power Supply Unit
a. Input power supply
(i.e. 3 Phase output of
stabiliser)
CHECK-UP
PERIOD
Daily
REMARKS
b. Panel cooling
Weekly
Weekly
Daily
c. E & W connections
d. U-V Table
To be
changed
after every 6
months.
DIELECTRIC SYSTEM
a. Clean the complete system
and hoses also.
b. Changing of water
c. Change the paper cartridge
filter (10 micron), in series
with filter pump.
Filter cleaning
Twice in a
Week
PART PROGRAMMING
SYSTEM
a. Single phase stabiliser
voltage output.
b. Computer unit cooling fan
c. Floppy drive reading head
Daily
Monthly
Page : 4 - 1
LOCATION
FUSE
NO.
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)
20 mm GLASS
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
10.
F3 EVTR-01
500 mA S.B.
20 MM GLASS
S.M.D. CONTROL
11.
F4 EVTR-01
500 mA S.B.
20 MM GLASS
S.M.D. CONTROL
12.
EVTR-02
4A F.B.
20 MM GLASS
HT. SMD
RATING
FUSE TYPE
USED FOR
Page : 4 - 2
CHAPTER V
MP-E1 RCU (Remote Control Unit)
4
A
10
1
5.0
10
LO JOG
HI
MP-E1
ELEKTRA
MP-E1
X-
HOME
Page : 5 - 1
HALT
PREJOG
Page : 5 - 2
WF
To Start dielectrics press this switch.
FLUSH
Page : 5 - 3