| The Wire Electric Discharge Machining (WEDM) shows a relatively small cutting force compared to traditional machining, so it is suitable for the machining of parts with complex shapes, high precision and hardness. This paper has done a serious of research in adaptive control including servo feed, varied-condition work piece on-line estimation, on-line adjustment of pulse power.This paper has pointed out the shortage of current WEDM control system, and has chose the adjusted parameter that can be done. A designing scheme of WEDM machining control system has been raised with DSP as the control core and adaptive control theory used by this paper.Self-tuning control theory has been used in the WEDM servo feed system in this paper. The ratio of short and sparkle of gap states has been used as information to put in the system, and realized adaptive control for the servo feed system. Servo feed has been tuned fast in wide scope, and stable high-efficient productivity has been achieved for machining varied-height work piece.On the basis of analyzing the relationship of machining power and etched energy in WEDM, a math formula has been got among height of work piece, displacement and discharge time. This paper has firstly established the math model of work piece height estimation fitted for WEDM-H, and has proposed a method of on-line tuning pulse power. Simulation of estimating height of work piece has been done by using self-adaptive control system. To test and verify these theories, a series trial has been done.This paper has designed an adaptive controller of WEDM and designed software. The paper has choices the TMS320LF2407 DSP as a core processor, which can process monitoring information and adaptive control algorithm fast. This controller has a power protecting function, and can been conveniently disposed by switches (in hardware side) and programming (in software side), and has many advantages including usually used, good reliability, conveniently used and so on.
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