CN108672860B - Z-axis intelligent lifting controller for wire cutting machine - Google Patents
Z-axis intelligent lifting controller for wire cutting machine Download PDFInfo
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- CN108672860B CN108672860B CN201810449532.1A CN201810449532A CN108672860B CN 108672860 B CN108672860 B CN 108672860B CN 201810449532 A CN201810449532 A CN 201810449532A CN 108672860 B CN108672860 B CN 108672860B
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- 238000001514 detection method Methods 0.000 claims abstract description 41
- 238000000819 phase cycle Methods 0.000 claims abstract description 23
- 239000003990 capacitor Substances 0.000 claims description 58
- 230000000087 stabilizing effect Effects 0.000 claims description 7
- 230000005669 field effect Effects 0.000 claims description 3
- 230000001681 protective effect Effects 0.000 claims 1
- 239000004973 liquid crystal related substance Substances 0.000 description 10
- 238000013461 design Methods 0.000 description 6
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- 230000007547 defect Effects 0.000 description 2
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- 238000012423 maintenance Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
- B23H7/14—Electric circuits specially adapted therefor, e.g. power supply
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P8/00—Arrangements for controlling dynamo-electric motors rotating step by step
- H02P8/14—Arrangements for controlling speed or speed and torque
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Abstract
The invention discloses a Z-axis intelligent lifting controller for a linear cutting machine, which comprises a power tube module, a driving power tube module, a protection power tube module, a current detection module, a power supply module, a main control module, a phase sequence detection module, a lifting stepping motor, a touch screen, a lifting limiting module and a signal input module. After power-on, the upper computer sends out a control signal of the driving motor, and the phase sequence detection module leads the effective signal into the signal input module by detecting the input control signal; then the main control module generates a PWM signal to the driving power tube module, and the power tube module is turned on or turned off under the action of the PWM signal, so that the stepping motor is driven to rotate or stop; and the Z-axis lifting stepping motor is the same, when the Z-axis lifting stepping motor reaches the limiting position, the limiting switch is pressed down to trigger the second optocoupler to output a low level, and the main control module drives the lifting stepping motor to stop after acquiring a low level signal, so that automatic lifting and limiting operation is realized, manual intervention is not needed, and the working efficiency is improved.
Description
Technical Field
The invention relates to the technical field of motor drive, in particular to a Z-axis intelligent lifting controller for a wire cutting machine.
Background
At present, the Z axis on the linear cutting machine is lifted by adopting a manual adjustment mode, a worker calculates the height to be lifted or lowered according to the processing requirement, and then the lifting of the Z axis is adjusted by manually adjusting a handle opposite to a graduated scale; the adjusting mode has the defects of low adjusting precision, easy error, large error and low efficiency. Accordingly, there is a need in the art for further improvements and perfection.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a Z-axis intelligent lifting controller which is simple in structure and used on a wire cutting machine.
The aim of the invention is achieved by the following technical scheme:
the Z-axis intelligent lifting controller mainly comprises a power tube module for driving one phase of a stepping motor, a driving power tube module for driving the power tube, a protection power tube module for protecting the power tube, a current detection module for detecting the current of the driving stepping motor, a power supply module for supplying power to each module, a main control module, a phase sequence detection module for detecting the driving phase sequence, a lifting stepping motor for driving the lifting of the Z-axis, a touch screen for setting the lifting amplitude and displaying system parameters, a lifting limiting module for positive and negative limiting and a signal input module for serving as a stepping motor driving main switch. The power tube module, the driving power tube module, the protection power tube module, the current detection module, the phase sequence detection module and the signal input module form a group of modules for controlling one phase of the stepping motor, and the number of the groups of the modules can be correspondingly increased according to the number of the stepping motors and the number of the phases in practical application, so that more stepping motors can be driven.
Specifically, the main control module is respectively connected with the touch screen, the lifting limiting module, the driving power tube module, the current detection module and the phase sequence detection module. The phase sequence detection module is connected with the signal input module. The power tube module is respectively connected with the stepping motor, the lifting stepping motor, the driving power tube module, the protection power tube module and the current detection module. The protection power tube module is connected with the stepping motor.
Specifically, the power tube module adopts an NMOS type field effect transistor, the drain electrode of the power tube module is respectively connected with one phase of the stepping motor and the protection power tube module, the source electrode of the power tube module is connected with the current detection module and then grounded, and the grid electrode of the power tube module is connected with the output end of the driving power tube module.
Specifically, the lifting limiting module is respectively arranged at the top and the bottom of the Z axis, and is used for limiting the working range of a workbench or a cutter positioned on the Z axis in the Z axis. The fourteenth capacitor and the nineteenth resistor are connected in parallel, one end of the parallel capacitor is connected with the first end of the second optocoupler, and the other end of the parallel capacitor is connected with the output end of the second light emitting diode. And the input end of the second light emitting diode is connected with the second end of the second optocoupler through a twentieth resistor. One end of the limit switch is grounded, and the other end of the limit switch is connected with the output end of the second light-emitting diode. The first end of the second optocoupler is connected with the second input voltage, the third end of the second optocoupler is grounded, the fourth end of the second optocoupler is connected with the output ends of the main control module and the power supply module through a twenty-first resistor, and the fourth end of the second optocoupler is grounded through a fifteenth capacitor. When the power tube module is used for driving the lifting stepping motor to move on the Z axis, when the power tube module reaches the upper limit position or the lower limit position of the Z axis, the formation switch is pressed to be connected with the ground, the input end of the second optocoupler is conducted, the second light emitting diode is lightened and prompts a worker, the output end of the second optocoupler is communicated to pull a pin which is originally at a high level to a low level, the signal is identified after reaching the main control module, the main control module stops driving the lifting motor, so that the working range is not exceeded, and the high-precision Z axis lifting control is realized; as for the magnitude and the speed of the lifting amplitude, the lifting amplitude can be input into the main control module through the touch screen to realize (or the parameters and the running state are displayed by the display screen, the parameters are transmitted through the keyboard or the keys or the running state of the lifting stepping motor is adjusted), so that the trouble of manually adjusting the lifting amplitude according to the Z-axis graduated scale is avoided, the working efficiency is obviously improved, and the adjusting time is shortened.
Specifically, in order to further reduce the cost, the touch screen in the scheme can be replaced by a scheme of adding keys to a common LCD, and the touch screen comprises an LCD liquid crystal screen for displaying information, a backlight module for improving the brightness of the LCD liquid crystal screen, and a key set for setting an input value or directly driving a lifting stepping motor (inching, continuous forward rotation or reverse rotation). The backlight module is arranged at the back of the LCD liquid crystal screen and connected with the main control module, and comprises a third light emitting diode, a second resistor, a third resistor, a fourth resistor, a fifth resistor and a fifth power tube; the third to eighth light-emitting diodes and the twenty-second to twenty-seventh resistors are connected in parallel with other groups after being connected in series with one diode and one resistor to form six groups of light-emitting channels. The input ends of the six groups of light-emitting channels are connected with the first output voltage, and the output ends are connected with the drain electrode of the fifth power tube. And the grid electrode of the fifth power tube is respectively connected with one end of the main control module and one end of the twenty-eighth resistor, and the source electrode of the fifth power tube is respectively connected with the ground end and the other end of the twenty-eighth resistor. When the LED display screen works, the main control module conducts the grid electrode of the fifth power tube by controlling the grid electrode of the fifth power tube, so that current passes through six groups of LEDs and generates bright light, the brightness of the LCD liquid crystal screen is improved, the display of the LCD liquid crystal screen is clear and visible, and the easiness of workers in acquiring screen information is improved.
Specifically, the main control module mainly comprises a main control chip for processing information of each module and realizing control, and a driving chip for generating PWM pulse signals. The driving chip is controlled by the main control chip, and the number of the chips is correspondingly increased according to the number and the phase number of stepping motors which are required to be driven, so that the structure of a driving circuit and the number of components are simplified, and the purposes of reducing the volume of the lifting controller and simplifying the design of the lifting controller are realized.
Specifically, the protection power tube module mainly comprises a seventeenth resistor, a second capacitor, a third diode, a fifth diode and a seventh diode which are connected in parallel. The output end of the third diode after being connected in parallel is connected with a first input voltage (the first input voltage is an external input voltage and adopts direct current 12V voltage), and the input end is respectively connected with the drain electrode of the power tube module and one end of the seventeenth resistor. One end of the second capacitor is grounded, and the other end of the second capacitor is connected with the other end of the second phase resistor. When the power tube is in operation, the seventeenth resistor and the second capacitor are connected in series and then are connected in parallel with the D pole and the S pole of the power tube, so as to absorb surge peak voltage generated by the rapid switch of the power tube, and the third diode, the fifth diode and the seventh diode are connected in parallel and then are used for releasing reverse electromotive force generated by a stepping motor coil (due to rapid on and off) to the VCC power supply loop, so that the power tube is protected from breakdown by the surge voltage.
Specifically, the current detection module mainly includes a fifteenth resistor, a sixteenth resistor, and a first capacitor. One end of the sixteenth resistor and one end of the fifteenth resistor are respectively connected with the source electrode of the power tube module, the other end of the sixteenth resistor is grounded, and the other end of the fifteenth resistor is respectively connected with the main control module and one end of the first capacitor. The other end of the first capacitor is grounded. When the stepping motor works, the main control module can calculate the working current when the stepping motor is conducted according to a formula by collecting the pressure difference between the source electrode of the power tube module and the power ground, so as to judge whether the stepping motor works under the rated working condition.
Specifically, the driving power tube module mainly includes a tenth resistor, an eleventh resistor, a thirteenth resistor, a first zener diode, a third triode, a fourth triode, and a fifth triode. The grid electrode of the power tube module is respectively connected with one end of a thirteenth resistor and the output end of a first voltage stabilizing diode, the input end of the first voltage stabilizing diode is grounded, and the other end of the thirteenth resistor is respectively connected with the emitter electrode of a fourth triode and the emitter electrode of a fifth triode. And the collector electrode of the fifth triode is grounded, and the base electrode is respectively connected with the base electrode of the fourth triode, the collector electrode of the third triode and one end of the eleventh resistor. The other end of the eleventh resistor is connected with the first input voltage and the collector electrode of the fourth triode respectively. And the emitter of the third triode is grounded, and the base is respectively connected with the main control module and one end of the tenth resistor. The other end of the tenth resistor is grounded. When the power tube module is driven by the complementary push-pull output formed by the fourth triode and the fifth triode in operation, the power tube module is simple in structure, high in stability and reliable in operation, the power tube module is quite suitable for driving a power tube, the third triode is adopted in the previous stage to generate a PWM pulse signal, the current power of the stepping motor can be effectively adjusted by controlling the time duty ratio of the high level and the low level in the PWM signal (when the actual power measured by the current detection module is smaller, the driving power of the stepping motor can be increased by adjusting the duty ratio), and therefore the stepping motor is ensured to work under constant power.
Specifically, the signal input module mainly includes a sixth resistor, an eighth resistor, a first diode, a first triode, and a second triode. The input end of the first diode is connected with the collector electrode of the third triode, and the output end of the first diode is respectively connected with one end of the eighth resistor and the collector electrode of the second triode. The emitter of the second triode is grounded, and the base is respectively connected with one end of the sixth resistor and the collector of the first triode. And the emitter electrode of the first triode is grounded. The other end of the sixth resistor is connected with the other end of the eighth resistor and the first input voltage respectively. When the signal input module works as a front-stage control switch for driving the power tube module, when the output end of the signal input module is at a high level, the PWM signal for driving the power tube module takes effect, otherwise, when the output end of the signal input module is at a low level, the power tube module is in a cut-off state (namely, the phase line of the stepping motor is not conducted).
Specifically, the phase sequence detection module receives a control signal of the upper computer and also receives a control signal of the main control module, and mainly comprises a first resistor, a second resistor, a fourth resistor, a fifth resistor, a twelfth resistor, a first optocoupler and a second zener diode. And the base electrode of the first triode is respectively connected with one end of the fourth resistor and one end of the fifth resistor and the third end of the first optocoupler. The other end of the fifth resistor is connected with the input end of the second voltage stabilizing diode and then grounded. The other end of the fourth resistor is connected with the output end of the second voltage stabilizing diode and then connected with the main control module. The fourth end of the first optocoupler is connected with the first input voltage through a twelfth resistor, the first end of the first optocoupler is connected with the second input voltage through the first resistor (the second input voltage is the same as the first input voltage in parameter but not in the same power network, so that the design is beneficial to effectively driving the optocoupler to work), and the second end of the first optocoupler is connected with the second end of the second optocoupler through the second resistor, and the second end of the second optocoupler is connected with the upper computer. When the phase-failure alarm module works, the main control module detects whether a control signal input by the upper computer has a phase-failure problem through the phase sequence detection module, and if the phase-failure problem occurs, the main control module drives the phase-failure alarm module to alarm, so that workers are reminded of timely processing.
Furthermore, in order to avoid the phenomenon that the precision of a workpiece is reduced or the size of the workpiece is inaccurate when the workpiece is cut because the stepping motor loses steps and is not perceived when the stepping motor loses steps, the Z-axis intelligent lifting controller for the linear cutting machine further comprises a phase-failure alarm module for prompting alarm information. The open-phase alarm module comprises a third resistor, a seventh triode and a first buzzer. And the base electrode of the seventh triode is connected with the main control module through a third resistor, the collector electrode of the seventh triode is connected with the first input voltage through a first buzzer, and the emitter electrode of the seventh triode is grounded. When detecting that the input signal or the stepping motor is out of phase, the main control module drives the first buzzer to send out alarm sounds, and the types of the sounds can be respectively set according to different types of errors, so that the on-site workers are reminded to timely detect the condition of the machine and do further maintenance work.
Furthermore, in order to be able to simply and intuitively display the working state of the stepping motor, the Z-axis intelligent lifting controller for the linear cutting machine further comprises an indication module for reflecting the working state of the motor. The indication module comprises a fourteenth resistor and a first light emitting diode. The output end of the first light-emitting diode is grounded, and the input end of the first light-emitting diode is connected with the grid electrode of the power tube module through a fourteenth resistor. When the power tube of a certain phase is conducted, the indicating lamp of the phase is lightened, so that the working state of the stepping motor in the phase can be intuitively seen.
Specifically, the power module mainly includes a first power chip, a first inductor, and fourth to thirteenth capacitors. The fourth capacitor and the tenth capacitor are respectively connected in parallel between the input end of the first power supply chip and the grounding end. The fifth capacitor and the eleventh capacitor are respectively connected in parallel between the output end of the first power chip and the grounding end. The output end of the first power supply chip is connected with the first inductor and generates a first output voltage (adopting a 5V voltage design). The sixth to ninth capacitances, and the twelfth and thirteenth capacitances are connected in parallel with the first output voltage and the power supply ground, respectively, at both ends thereof. The input end of the first power supply chip is connected with a first input voltage.
Furthermore, in order to enable the lifting controller to reset normally when being electrified and adjust the system parameters to the original positions, the lifting controller also comprises a reset module for resetting the main control module, wherein the reset module corresponds to the number of the driving chips and the control chips in the main control module one by one and mainly comprises an eighteenth resistor, a third capacitor and a first reset chip. The two ends of the eighteenth resistor are connected in parallel between the input end and the reset end of the first reset chip. And two ends of the third capacitor are connected in parallel between the reset end of the first reset chip and the grounding end. The input end of the first reset chip is connected with the first output voltage, the reset end is connected with the main control module, and the grounding end is connected with the power supply ground.
The working process and principle of the invention are as follows: when the lifting controller is connected with a power supply, the reset module generates a reset signal to reset a chip in the main control module and refresh a parameter set value; then, the upper computer sends out a control signal of the driving motor, and the phase sequence detection module detects the input control signal to remove the phase-failure signal and inputs the effective control signal to the signal input module; then, the main control module generates a PWM signal for controlling the stepping motor to the driving power tube module, and the power tube module is switched on or off according to the PWM signal, so that the stepping motor is controlled to be switched on or off on the phase line; the lifting stepping motor on the Z axis is driven in the same way, when the Z axis sliding block reaches the upper limit position or the lower limit position, the limit switch is pressed down, so that the second optocoupler is triggered to output a low level at the output end and light the second light emitting diode to serve as a prompt signal, and after the main control module acquires the low level signal, the lifting stepping motor is driven to stop and prompt the lifting stepping motor to exceed the travel range, thereby realizing automatic lifting and limit operation of the Z axis sliding block, avoiding manual intervention, saving time cost and improving working efficiency. The invention also has the advantages of simple structure, convenient operation and easy implementation.
Compared with the prior art, the invention has the following advantages:
(1) The Z-axis intelligent lifting controller for the linear cutting machine provided by the invention adopts the phase-failure detection and phase-failure alarm module to remind on-site workers that the machine needs to be overhauled or adjusted, thereby ensuring that the stepping motor works under stable and proper working conditions and being beneficial to unification and improvement of cutting quality.
(2) Compared with the traditional current-limiting resistance type driving mode, the intelligent Z-axis lifting controller for the linear cutting machine provided by the invention has the advantages of adjustable power, stable power, low energy consumption, low cost, simple structure and the like.
(3) The Z-axis intelligent lifting controller for the cutting machine provided by the invention converts the position signal into the corresponding electric signal and optical signal by adopting a mode of matching a limit switch with an optical coupler for driving, and sends warning information to a main control module and site workers, so that the warning information is processed in time, the time and steps of manual adjustment are saved, and the production efficiency of linear cutting is improved.
Drawings
Fig. 1 is a circuit structure diagram of each module of the intelligent Z-axis lifting controller for the wire cutting machine.
Fig. 2 is a circuit configuration diagram of a reset module provided by the present invention.
Fig. 3 is a circuit configuration diagram of a power module provided by the present invention.
Fig. 4 is a circuit configuration diagram of the lifting limit module provided by the invention.
Fig. 5 is a circuit configuration diagram of a backlight module provided by the present invention.
The reference numerals in the above figures illustrate:
q5-fifth power tube, Q6-power tube module, Z1-first zener diode, Z2-second zener diode, IC 1-first optocoupler, IC 2-first reset chip, IC 3-first power chip, IC 4-second optocoupler, LED 1-first light emitting diode, LED 2-second light emitting diode, LED 3-third light emitting diode, LED 4-fourth light emitting diode, LED 5-fifth light emitting diode, LED 6-sixth light emitting diode, LED 7-seventh light emitting diode, LED 8-eighth light emitting diode, S1-limit switch, VDDA-first input voltage, VDDB-second input voltage, L1-first inductor.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more clear and clear, the present invention will be further described below with reference to the accompanying drawings and examples.
Example 1: as shown in fig. 1, 2, 3 and 4, the invention discloses a Z-axis intelligent lifting controller for a linear cutting machine, which mainly comprises a power tube module Q6 for driving one phase of a stepping motor, a driving power tube module for driving the power tube, a protection power tube module for protecting the power tube, a current detection module for detecting the current of the driving stepping motor, a power supply module for supplying power to each module, a main control module, a phase sequence detection module for detecting the driving phase sequence, a lifting stepping motor for driving the lifting of the Z-axis, a touch screen for setting the lifting amplitude and displaying system parameters, a lifting limit module for positive and negative limit, and a signal input module as a main driving switch of the stepping motor. The power tube module Q6, the driving power tube module, the protection power tube module, the current detection module, the phase sequence detection module and the signal input module form a group of modules for controlling one phase of the stepping motor, and the number of the groups of the modules can be correspondingly increased according to the number of the stepping motors and the number of the phases in practical application, so that more stepping motors can be driven.
Specifically, the main control module is respectively connected with the touch screen, the lifting limiting module, the driving power tube module, the current detection module and the phase sequence detection module. The phase sequence detection module is connected with the signal input module. The power tube module Q6 is respectively connected with the stepping motor, the lifting stepping motor, the driving power tube module, the protection power tube module and the current detection module. The protection power tube module is connected with the stepping motor.
Specifically, the power tube module Q6 adopts an NMOS field effect transistor, the drain electrode of the power tube module Q6 is connected with a phase of the stepper motor and the protection power tube module respectively, the source electrode of the power tube module Q6 is connected with the current detection module and then grounded, and the gate electrode of the power tube module Q6 is connected with the output end of the driving power tube module.
Specifically, the lifting limiting modules are respectively arranged at the top and the bottom of the Z axis, and respectively limit the working range of a workbench or a cutter positioned on the Z axis in the Z axis, and the structure mainly comprises a second optocoupler IC4, a second light emitting diode LED2, a nineteenth resistor, a twentieth resistor, a twenty first resistor, a fourteenth capacitor, a fifteenth capacitor and a limiting switch S1. The fourteenth capacitor and the nineteenth resistor are connected in parallel, one end of the parallel connection is connected with the first end of the second optocoupler IC4, and the other end of the parallel connection is connected with the output end of the second light emitting diode LED 2. The input end of the second light emitting diode LED2 is connected with the second end of the second optocoupler IC4 through a twentieth resistor. One end of the limit switch S1 is grounded, and the other end of the limit switch S1 is connected with the output end of the second light-emitting diode LED 2. The first end of the second optocoupler IC4 is connected with the second input voltage VDDB, the third end is grounded, the fourth end is connected with the output ends of the main control module and the power supply module through a twenty-first resistor, and the fourth end is grounded through a fifteenth capacitor. When the power tube module Q6 is used for driving the lifting stepping motor to move on the Z axis, when the upper limit position or the lower limit position of the Z axis is reached, the formation switch is pressed to be connected with the ground, the input end of the second optocoupler IC4 is conducted, the second light emitting diode LED2 is lightened and prompts a worker, the output end of the second optocoupler IC4 is communicated to pull a pin which is originally in a high level to a low level, the signal is identified after reaching the main control module, the main control module stops driving the lifting motor, and therefore the working range is not exceeded, and high-precision Z axis lifting control is realized; as for the magnitude and the speed of the lifting amplitude, the lifting amplitude can be input into the main control module through the touch screen to realize (or the parameters and the running state are displayed by utilizing the display screen, the parameters are input through a keyboard or keys or the running state of the lifting stepping motor is adjusted), the trouble of manually adjusting the lifting amplitude according to the Z-axis graduated scale is avoided, the working efficiency is obviously improved, and the adjusting time is shortened.
Specifically, as shown in fig. 5, in order to further reduce the cost, the touch screen in the present solution may be replaced by a solution of adding keys to a common LCD, including an LCD liquid crystal screen for displaying information, a backlight module for improving the brightness of the LCD liquid crystal screen, and a key set for setting an input value or directly driving a lifting stepping motor (inching, continuous forward rotation or reverse rotation). The backlight module is arranged at the back of the LCD liquid crystal screen and connected with the main control module, and comprises third to eighth light emitting diodes (LED 3 to LED 8), twenty-second to twenty-eighth resistors and a fifth power tube Q5; the third to eighth light emitting diodes LED3 to LED8 and the twenty-second to twenty-seventh resistors are connected in parallel with other groups after being connected in series with one diode to form six groups of light emitting channels. The input ends of the six groups of light-emitting channels are connected with the first output voltage VDDA, and the output ends of the six groups of light-emitting channels are connected with the drain electrode of the fifth power tube Q5. And the grid electrode of the fifth power tube Q5 is respectively connected with one end of the main control module and one end of the twenty-eighth resistor, and the source electrode is respectively connected with the ground end and the other end of the twenty-eighth resistor. When the LED display screen works, the main control module conducts the fifth power tube Q5 by controlling the grid electrode of the fifth power tube Q5, so that current passes through six groups of light emitting diodes and generates bright light, the brightness of the LCD liquid crystal screen is improved, the display of the LCD liquid crystal screen is clear and visible, and the easiness of workers in acquiring screen information is improved.
Specifically, the main control module mainly comprises a main control chip for processing information of each module and realizing control, and a driving chip for generating PWM pulse signals. The driving chip is controlled by the main control chip, and the number of the chips is correspondingly increased according to the number and the phase number of stepping motors which are required to be driven, so that the structure of a driving circuit and the number of components are simplified, and the purposes of reducing the volume of the lifting controller and simplifying the design of the lifting controller are realized.
Specifically, the protection power tube module mainly comprises a seventeenth resistor, a second capacitor, a third diode, a fifth diode and a seventh diode which are connected in parallel. The output end of the third diode after being connected in parallel is connected with a first input voltage VDDA (the first input voltage VDDA is an external input voltage and adopts direct current 12V voltage), and the input end is respectively connected with the drain electrode of the power tube module Q6 and one end of a seventeenth resistor. One end of the second capacitor is grounded, and the other end of the second capacitor is connected with the other end of the second phase resistor. When the power tube is in operation, the seventeenth resistor and the second capacitor are connected in series and then are connected in parallel with the D pole and the S pole of the power tube, so as to absorb surge peak voltage generated by the rapid switch of the power tube, and the third diode, the fifth diode and the seventh diode are connected in parallel and then are used for releasing reverse electromotive force generated by a stepping motor coil (due to rapid on and off) to the VCC power supply loop, so that the power tube is protected from breakdown by the surge voltage.
Specifically, the current detection module mainly includes a fifteenth resistor, a sixteenth resistor, and a first capacitor. One end of the sixteenth resistor and one end of the fifteenth resistor are respectively connected with the source electrode of the power tube module Q6, the other end of the sixteenth resistor is grounded, and the other end of the fifteenth resistor is respectively connected with the main control module and one end of the first capacitor. The other end of the first capacitor is grounded. When the stepping motor works, the main control module can calculate the working current when the stepping motor is conducted according to a formula by collecting the pressure difference between the source electrode of the power tube module Q6 and the power ground, so as to judge whether the stepping motor works under the rated working condition.
Specifically, the driving power tube module mainly includes a tenth resistor, an eleventh resistor, a thirteenth resistor, a first zener diode Z1, a third triode, a fourth triode, and a fifth triode. The grid electrode of the power tube module Q6 is respectively connected with one end of a thirteenth resistor and the output end of the first zener diode Z1, the input end of the first zener diode Z1 is grounded, and the other end of the thirteenth resistor is respectively connected with the emitter electrode of the fourth triode and the emitter electrode of the fifth triode. And the collector electrode of the fifth triode is grounded, and the base electrode is respectively connected with the base electrode of the fourth triode, the collector electrode of the third triode and one end of the eleventh resistor. The other end of the eleventh resistor is connected with the first input voltage VDDA and the collector electrode of the fourth triode respectively. And the emitter of the third triode is grounded, and the base is respectively connected with the main control module and one end of the tenth resistor. The other end of the tenth resistor is grounded. When the power tube module is driven by the complementary push-pull output formed by the fourth triode and the fifth triode in operation, the power tube module is simple in structure, high in stability and reliable in operation, the power tube module is quite suitable for driving a power tube, the third triode is adopted in the previous stage to generate a PWM pulse signal, the current power of the stepping motor can be effectively adjusted by controlling the time duty ratio of the high level and the low level in the PWM signal (when the actual power measured by the current detection module is smaller, the driving power of the stepping motor can be increased by adjusting the duty ratio), and therefore the stepping motor is ensured to work under constant power.
Specifically, the signal input module mainly includes a sixth resistor, an eighth resistor, a first diode, a first triode, and a second triode. The input end of the first diode is connected with the collector electrode of the third triode, and the output end of the first diode is respectively connected with one end of the eighth resistor and the collector electrode of the second triode. The emitter of the second triode is grounded, and the base is respectively connected with one end of the sixth resistor and the collector of the first triode. And the emitter electrode of the first triode is grounded. The other end of the sixth resistor is connected with the other end of the eighth resistor and the first input voltage VDDA respectively. When the power tube module works, the signal input module is used as a front-stage control switch for driving the power tube module, when the output end of the signal input module is at a high level, the PWM signal for driving the power tube module takes effect, otherwise, when the output end of the signal input module is at a low level, the power tube module Q6 is in a cut-off state (namely, the phase line of the stepping motor is not conducted).
Specifically, the phase sequence detection module receives a control signal of the upper computer and also receives a control signal of the main control module, and mainly comprises a first resistor, a second resistor, a fourth resistor, a fifth resistor, a twelfth resistor, a first optocoupler IC1 and a second zener diode Z2. The base electrode of the first triode is respectively connected with one end of the fourth resistor and one end of the fifth resistor and the third end of the first optocoupler IC 1. The other end of the fifth resistor is connected with the input end of the second zener diode Z2 and then grounded. The other end of the fourth resistor is connected with the output end of the second zener diode Z2 and then connected with the main control module. The fourth end of the first optocoupler IC1 is connected to the first input voltage VDDA through a twelfth resistor, the first end is connected to the second input voltage VDDB through the first resistor (the second input voltage VDDB is the same as the first input voltage VDDA in parameter but not in the same power network, so that the design is beneficial to effectively driving the optocoupler to work), and the second end is connected to the second end through the second resistor, and the second end is connected to the upper computer. When the phase-failure alarm module works, the main control module detects whether a control signal input by the upper computer has a phase-failure problem through the phase sequence detection module, and if the phase-failure problem occurs, the main control module drives the phase-failure alarm module to alarm, so that workers are reminded of timely processing.
Furthermore, in order to avoid the phenomenon that the precision of a workpiece is reduced or the size of the workpiece is inaccurate when the workpiece is cut because the stepping motor loses steps and is not perceived when the stepping motor loses steps, the Z-axis intelligent lifting controller for the linear cutting machine further comprises a phase-failure alarm module for prompting alarm information. The open-phase alarm module comprises a third resistor, a seventh triode and a first buzzer. And the base electrode of the seventh triode is connected with the main control module through a third resistor, the collector electrode of the seventh triode is connected with the first input voltage VDDA through a first buzzer, and the emitter electrode of the seventh triode is grounded. When detecting that the input signal or the stepping motor is out of phase, the main control module drives the first buzzer to send out alarm sounds, and the types of the sounds can be respectively set according to different types of errors, so that the on-site workers are reminded to timely detect the condition of the machine and do further maintenance work.
Furthermore, in order to be able to simply and intuitively display the working state of the stepping motor, the Z-axis intelligent lifting controller for the linear cutting machine further comprises an indication module for reflecting the working state of the motor. The indication module comprises a fourteenth resistor and a first light emitting diode LED1. The output end of the first light emitting diode LED1 is grounded, and the input end of the first light emitting diode LED1 is connected with the grid electrode of the power tube module Q6 through a fourteenth resistor. When the power tube of a certain phase is conducted, the indicating lamp of the phase is lightened, so that the working state of the stepping motor in the phase can be intuitively seen.
Specifically, the power module mainly includes a first power chip IC3, a first inductor L1, and fourth to thirteenth capacitors. The fourth capacitor and the tenth capacitor are respectively connected in parallel between the input end of the first power chip IC3 and the ground end. The fifth capacitor and the eleventh capacitor are respectively connected in parallel between the output end of the first power chip IC3 and the grounding end. The output end of the first power chip IC3 is connected to the first inductor L1 and generates a first output voltage (using a 5V voltage design). The sixth to ninth capacitances, and the twelfth and thirteenth capacitances are connected in parallel with the first output voltage and the power supply ground, respectively, at both ends thereof. The input terminal of the first power chip IC3 is connected to the first input voltage VDDA.
Furthermore, in order to enable the lifting controller to reset normally when being electrified and adjust the system parameters to the original positions, the lifting controller also comprises a reset module for resetting the main control module, wherein the reset module corresponds to the number of the driving chips and the control chips in the main control module one by one and mainly comprises an eighteenth resistor, a third capacitor and a first reset chip IC2. The two ends of the eighteenth resistor are connected in parallel between the input end and the reset end of the first reset chip IC2. The two ends of the third capacitor are connected in parallel between the reset end of the first reset chip IC2 and the ground end. The input end of the first reset chip IC2 is connected with the first output voltage, the reset end is connected with the main control module, and the grounding end is connected with the power supply ground.
The working process and principle of the invention are as follows: when the lifting controller is connected with a power supply, the reset module generates a reset signal to reset a chip in the main control module and refresh a parameter set value; then, the upper computer sends out a control signal of the driving motor, and the phase sequence detection module detects the input control signal to remove the phase-failure signal and inputs the effective control signal to the signal input module; then, the main control module generates a PWM signal for controlling the stepping motor to the driving power tube module, and the power tube module Q6 is switched on or off according to the PWM signal, so that the stepping motor is controlled to be switched on or off on the phase line; the same driving is adopted by the lifting stepping motor on the Z axis, when the Z axis sliding block reaches the upper limit position or the lower limit position, the limit switch S1 is pressed down, so that the second optocoupler IC4 is triggered to output a low level at the output end and light the second light emitting diode LED2 to serve as a prompt signal, and after the main control module acquires the low level signal, the lifting stepping motor is driven to stop and prompt the lifting stepping motor to exceed the travel range, thereby realizing the automatic lifting and limit operation of the Z axis sliding block, avoiding manual intervention, saving time cost and improving working efficiency. The invention also has the advantages of simple structure, convenient operation and easy implementation.
The above examples are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above examples, and any other changes, modifications, substitutions, combinations, and simplifications that do not depart from the spirit and principle of the present invention should be made in the equivalent manner, and the embodiments are included in the protection scope of the present invention.
Claims (10)
1. The Z-axis intelligent lifting controller for the linear cutting machine is characterized by comprising a power tube module for driving one phase of a stepping motor, a driving power tube module for driving the power tube, a protection power tube module for protecting the power tube, a current detection module for detecting the current of the driving stepping motor, a power supply module for supplying power to each module, a main control module, a phase sequence detection module for detecting the driving phase sequence, a lifting stepping motor for driving the lifting of the Z-axis, a touch screen for setting the lifting amplitude and displaying system parameters, a lifting limit module for positive and negative limit and a signal input module as a stepping motor driving main switch;
the main control module is respectively connected with the touch screen, the lifting limiting module, the driving power tube module, the current detection module and the phase sequence detection module; the phase sequence detection module is connected with the signal input module; the power tube module is respectively connected with the stepping motor, the lifting stepping motor, the driving power tube module, the protection power tube module and the current detection module; the protection power tube module is connected with the stepping motor;
the power tube module adopts an NMOS type field effect transistor, the drain electrode of the power tube module is respectively connected with one phase of the stepping motor and the protection power tube module, the source electrode of the power tube module is connected with the current detection module and then grounded, and the grid electrode of the power tube module is connected with the output end of the driving power tube module;
the lifting limit module is respectively arranged at the top and the bottom of the Z axis and comprises a second optocoupler, a second light emitting diode, a nineteenth resistor, a twentieth resistor, a twenty first resistor, a fourteenth capacitor, a fifteenth capacitor and a limit switch; the fourteenth capacitor and the nineteenth resistor are connected in parallel, one end of the connected capacitor is connected with the first end of the second optocoupler, and the other end of the connected capacitor is connected with the output end of the second light-emitting diode; the input end of the second light-emitting diode is connected with the second end of the second optocoupler through a twentieth resistor; one end of the limit switch is grounded, and the other end of the limit switch is connected with the output end of the second light-emitting diode; the first end of the second optocoupler is connected with the second input voltage, the third end of the second optocoupler is grounded, the fourth end of the second optocoupler is connected with the output ends of the main control module and the power supply module through a twenty-first resistor, and the fourth end of the second optocoupler is grounded through a fifteenth capacitor.
2. The intelligent Z-axis lift controller for use on a wire cutting machine of claim 1, wherein the protective power tube module comprises a seventeenth resistor, a second capacitor, and a third diode, a fifth diode, and a seventh diode connected in parallel with each other; the output end of the third diode after being connected in parallel is connected with a first input voltage, and the input end of the third diode is respectively connected with the drain electrode of the power tube module and one end of a seventeenth resistor; one end of the second capacitor is grounded, and the other end of the second capacitor is connected with the other end of the seventeenth resistor.
3. The Z-axis intelligent lift controller for use on a wire cutting machine of claim 1, wherein the current detection module comprises a fifteenth resistor, a sixteenth resistor, and a first capacitor; one end of the sixteenth resistor and one end of the fifteenth resistor are respectively connected with the source electrode of the power tube module, the other end of the sixteenth resistor is grounded, and the other end of the fifteenth resistor is respectively connected with the main control module and one end of the first capacitor; the other end of the first capacitor is grounded.
4. The intelligent Z-axis lift controller for use on a wire cutting machine of claim 1, wherein the drive power tube module comprises a tenth resistor, an eleventh resistor, a thirteenth resistor, a first zener diode, a third triode, a fourth triode, and a fifth triode; the grid electrode of the power tube module is respectively connected with one end of a thirteenth resistor and the output end of a first voltage stabilizing diode, the input end of the first voltage stabilizing diode is grounded, and the other end of the thirteenth resistor is respectively connected with the emitter electrode of a fourth triode and the emitter electrode of a fifth triode; the collector electrode of the fifth triode is grounded, and the base electrode is respectively connected with the base electrode of the fourth triode, the collector electrode of the third triode and one end of the eleventh resistor; the other end of the eleventh resistor is connected with the first input voltage and the collector electrode of the fourth triode respectively; the emitter of the third triode is grounded, and the base is respectively connected with the main control module and one end of the tenth resistor; the other end of the tenth resistor is grounded.
5. The intelligent Z-axis lift controller for use on a wire cutting machine of claim 4, wherein the signal input module comprises a sixth resistor, an eighth resistor, a first diode, a first triode, and a second triode; the input end of the first diode is connected with the collector electrode of the third triode, and the output end of the first diode is respectively connected with one end of the eighth resistor and the collector electrode of the second triode; the emitter of the second triode is grounded, and the base is respectively connected with one end of the sixth resistor and the collector of the first triode; the emitter electrode of the first triode is grounded; the other end of the sixth resistor is connected with the other end of the eighth resistor and the first input voltage respectively.
6. The intelligent Z-axis lift controller for use on a wire cutting machine of claim 5, wherein the phase sequence detection module comprises a first resistor, a second resistor, a fourth resistor, a fifth resistor, a twelfth resistor, a first optocoupler, and a second zener diode; the base electrode of the first triode is respectively connected with one end of the fourth resistor and one end of the fifth resistor and the third end of the first optocoupler; the other end of the fifth resistor is connected with the input end of the second voltage stabilizing diode and then grounded; the other end of the fourth resistor is connected with the output end of the second voltage-stabilizing diode and then connected with the main control module; the fourth end of the first optocoupler is connected with the first input voltage through a twelfth resistor, the first end of the first optocoupler is connected with the second input voltage through the first resistor, the second optocoupler is connected with the second end through the second resistor, and the second end of the first optocoupler is connected with the upper computer.
7. The intelligent Z-axis lifting controller for a wire cutting machine according to claim 1, wherein the intelligent Z-axis lifting controller for a wire cutting machine further comprises a phase failure alarm module for prompting alarm information; the open-phase alarm module comprises a third resistor, a seventh triode and a first buzzer; and the base electrode of the seventh triode is connected with the main control module through a third resistor, the collector electrode of the seventh triode is connected with the first input voltage through a first buzzer, and the emitter electrode of the seventh triode is grounded.
8. The intelligent Z-axis lifting controller for a wire cutting machine according to claim 1, wherein the intelligent Z-axis lifting controller for a wire cutting machine further comprises an indication module for reflecting the working state of a motor; the indicating module comprises a fourteenth resistor and a first light-emitting diode; the output end of the first light-emitting diode is grounded, and the input end of the first light-emitting diode is connected with the grid electrode of the power tube module through a fourteenth resistor.
9. The Z-axis intelligent lift controller for use on a wire cutting machine of claim 1, wherein the power module comprises a first power chip, a first inductor, and fourth to thirteenth capacitors; the fourth capacitor and the tenth capacitor are respectively connected in parallel between the input end of the first power supply chip and the grounding end; the fifth capacitor and the eleventh capacitor are respectively connected in parallel between the output end of the first power chip and the grounding end; the output end of the first power supply chip is connected with the first inductor and generates a first output voltage; the two ends of the sixth to ninth capacitors, the twelfth capacitor and the thirteenth capacitor are respectively connected with the first output voltage and the power ground in parallel; the input end of the first power supply chip is connected with a first input voltage.
10. The intelligent Z-axis lifting controller for a wire cutting machine according to claim 9, further comprising a reset module for resetting the main control module, wherein the reset module comprises an eighteenth resistor, a third capacitor and a first reset chip; the two ends of the eighteenth resistor are connected in parallel between the input end and the reset end of the first reset chip; the two ends of the third capacitor are connected in parallel between the reset end of the first reset chip and the grounding end; the input end of the first reset chip is connected with the first output voltage, the reset end is connected with the main control module, and the grounding end is connected with the power supply ground.
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