Self-adaptive roller group for medium-speed wire electrode wire tension

Abstract

The utility model discloses a kind of middle wire electrode wire tension self-adapting roller groups, including outer shell, driving wheel, driven wheel, tension wheel, telescopic tension arm, piston rod, threaded sleeve and threaded adjusting rod, driving wheel surface is provided with spiral groove anti-skid line, driven wheel is matched with high-precision bearing, tension wheel uses light wear-resistant ceramic material and installs high-precision displacement sensor, telescopic tension arm contains stainless steel telescopic rod and return spring, realizes tension dynamic compensation;Piston rod is plated with chromium to improve durability, threaded adjusting structure cooperates with guide key to ensure adjusting accuracy, each component is optimized design, driving wheel, driven wheel and tension wheel are balanced tension distribution with 2:1.5:1 wheel diameter ratio.The roller group can effectively prevent electrode wire from slipping, reduce tension fluctuation, monitor tension change in real time, accurately adjust compensation, improve electrode wire running stability and machining precision, reduce wear, applicable to the high-precision control demand of electrode wire tension for middle wire machining.

Description

Technical Field

[0001] This utility model relates to the technical field of wire electrical discharge machining equipment, specifically to an adaptive roller assembly for the tension of a medium-speed wire electrode. Background Technology

[0002] In the process of medium-speed wire EDM, the tension stability of the electrode wire directly affects the machining accuracy and surface quality.

[0003] Traditional wire EDM machines suffer from the following problems in electrode wire tension control: 1. During wire EDM, the friction between the drive wheel and the electrode wire in traditional roller sets is insufficient, and the wheel surface lacks an effective anti-slip design, causing the electrode wire to slip easily, affecting machining accuracy and stability, and reducing machining quality and efficiency; 2. The tension is not adjustable or has a limited adjustment range, making it difficult to adapt to the machining requirements of workpieces of different materials and thicknesses; 3. Traditional roller sets lack high-precision tension monitoring methods, making it impossible to accurately obtain the electrode wire tension status in real time, which is not conducive to timely adjustment and optimization of machining parameters, and makes it difficult to ensure the stability of machining quality.

[0004] Therefore, it is necessary to design an adaptive roller assembly for the wire tension of the wire feed electrode to solve the problems mentioned above. Utility Model Content

[0005] The purpose of this invention is to provide an adaptive roller assembly for the tension of the wire in a medium-speed wire electrode, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] The adaptive tension roller assembly for wire-feed electrodes includes outer housings on the left and right sides for mounting. Between the outer housings are a drive wheel located on the upper front side, a driven wheel located on the upper rear side, and a tension wheel located below the drive wheel and the driven wheel. A telescopic tension arm is connected to the outer side of the tension wheel. Telescopic piston rods are located on the front and rear sides at the upper position between the left and right outer housings. A threaded sleeve and a threaded adjusting rod are located at the middle position between the left and right outer housings. The left and right sides of the threaded adjusting rod are threadedly connected to the inside of the threaded sleeve.

[0008] As a preferred embodiment of this utility model, the surface of the drive wheel is provided with anti-slip texture, which is a spiral groove with a depth of 0.5-1mm and a pitch of 2-3mm, in order to increase the friction between the drive wheel and the electrode wire and prevent the electrode wire from slipping.

[0009] As a preferred embodiment of this utility model, a high-precision bearing is installed between the central shaft of the driven wheel and the outer shell. The radial runout error of the bearing does not exceed 0.01mm, ensuring the smooth rotation of the driven wheel and reducing the tension fluctuation of the electrode wire.

[0010] As a preferred embodiment of this utility model, the tension wheel is made of lightweight and wear-resistant ceramic material with a surface roughness of no more than Ra0.4μm, which reduces its own weight, extends its service life, and reduces wear on the electrode wire.

[0011] As a preferred embodiment of this utility model, the telescopic tension arm includes a telescopic rod and a return spring. The telescopic rod is made of stainless steel with a hardness of HRC30-35, and the spring constant is 5-10 N / mm. When the electrode wire tension changes, the telescopic tension arm can flexibly extend and retract and provide corresponding tension compensation.

[0012] As a preferred embodiment of this utility model, the piston rod has a telescopic stroke of 10-20mm, and its surface is chrome-plated with a chrome plating layer thickness of 0.02-0.05mm to improve the wear resistance and corrosion resistance of the piston rod and ensure its smooth telescopic movement.

[0013] As a preferred embodiment of this utility model, the inner wall of the threaded sleeve is provided with a guide keyway, and the threaded adjusting rod is provided with a guide key that cooperates with the guide keyway. The guide keyway has a depth of 2-3mm and a width of 5-6mm to ensure that the threaded adjusting rod does not circumferentially shift when rotating inside the threaded sleeve, thus ensuring adjustment accuracy.

[0014] As a preferred embodiment of this utility model, a displacement sensor is also provided on the tension wheel. The displacement sensor is a high-precision linear displacement sensor with a measurement accuracy of up to 0.01 mm, which can accurately monitor the displacement change of the tension wheel in real time and thus provide feedback on the real-time state of the electrode wire tension.

[0015] As a preferred embodiment of this utility model, the diameter ratio of the driving wheel, the driven wheel, and the tension wheel is 2:1.5:1. The optimized diameter ratio can effectively balance the tension distribution of the electrode wire on the roller assembly and improve the stability of the electrode wire operation.

[0016] Compared with the prior art, the beneficial effects of this utility model are:

[0017] In this invention, the adaptive roller assembly for the wire tension of the wire electrode achieves the following effects: 1. The drive roller has a spiral groove anti-slip pattern on its surface, with a depth of 0.5-1mm and a pitch of 2-3mm, increasing the friction between the drive roller and the wire electrode, effectively preventing wire slippage, ensuring stable machining, and improving machining accuracy and efficiency; 2. A high-precision bearing is installed between the driven roller's central shaft and the outer casing, with a radial runout error not exceeding 0.01mm, ensuring smooth rotation of the driven roller, reducing wire tension fluctuations, ensuring machining accuracy and consistency, and reducing wire wear; 3. The tension roller is made of lightweight, wear-resistant ceramic material with a surface roughness of no more than Ra0.4μm, reducing its weight and inertia, making it more sensitive to changes in wire tension, extending its service life, and reducing replacement frequency and maintenance costs; the tension roller is equipped with a high-precision linear displacement sensor with a measurement accuracy of 0.01mm for real-time accurate monitoring. 4. The tension wheel displacement change provides real-time feedback on the electrode wire tension, allowing operators to adjust processing parameters promptly and ensuring stable processing quality; 5. The telescopic tension arm includes a stainless steel telescopic rod with a hardness of HRC30-35 and a return spring with an elastic coefficient of 5-10 N / mm, which can flexibly extend and retract when the electrode wire tension changes, providing timely tension compensation, maintaining stable electrode wire tension, and ensuring processing accuracy and electrode wire lifespan; 6. The guide keyway on the inner wall of the threaded sleeve cooperates with the guide key of the threaded adjusting rod. The guide keyway depth is 2-3 mm and the width is 5-6 mm, preventing circumferential offset when the threaded adjusting rod rotates, accurately controlling the adjustment amount, and meeting the requirements of high-precision machining for electrode wire tension adjustment; The piston rod has a telescopic stroke of 10-20 mm, with a chrome-plated surface and a chrome plating layer thickness of 0.02-0.05 mm, improving wear resistance and corrosion resistance, ensuring smooth extension and retraction, extending component lifespan, and reducing equipment maintenance frequency and costs. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall three-dimensional structure of this utility model;

[0019] Figure 2 This is a side view of the structure of this utility model;

[0020] Figure 3 This is a schematic diagram of the main structure of this utility model.

[0021] In the diagram: 1. Outer shell; 2. Drive wheel; 3. Driven wheel; 4. Tension wheel; 5. Telescopic tension arm; 6. Piston rod; 7. Threaded sleeve; 8. Threaded adjusting rod; 9. Displacement sensor. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0023] To facilitate understanding of this utility model, a more comprehensive description will be given below with reference to the accompanying drawings. Several embodiments of this utility model are provided. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this utility model will be more thorough and complete.

[0024] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0026] For examples, please refer to Figure 1-3 This utility model provides a technical solution:

[0027] The adaptive tension roller assembly for wire feed electrode includes an outer housing 1 located on the left and right sides for mounting. Between the outer housing 1, there is a drive wheel 2 located on the upper front side, a driven wheel 3 located on the upper rear side, and a tension wheel 4 located below the drive wheel 2 and the driven wheel 3. A telescopic tension arm 5 is connected to the outside of the tension wheel 4. Telescopic piston rods 6 are located on the front and rear sides at the upper position between the left and right outer housing 1. A threaded sleeve 7 and a threaded adjusting rod 8 are located in the middle position between the left and right outer housing 1. The left and right sides of the threaded adjusting rod 8 are threadedly connected to the inside of the threaded sleeve 7.

[0028] Specifically, the surface of the drive wheel 2 is provided with anti-slip grooves, which are spiral grooves with a depth of 0.5-1mm and a pitch of 2-3mm, to increase the friction between the drive wheel and the electrode wire and prevent the electrode wire from slipping. The electrode wire contacts the surface of the drive wheel 2, and during the transmission process, the friction between the electrode wire and the spiral groove anti-slip grooves on the wheel surface generates the electrode wire, driving the electrode wire to move. The anti-slip grooves are 0.5-1mm deep and 2-3mm pitched, which increases the friction between the drive wheel and the electrode wire, prevents the electrode wire from slipping, ensures the stability of the machining process, and improves machining accuracy and efficiency.

[0029] Specifically, a high-precision bearing is installed between the central shaft of the driven wheel 3 and the outer shell 1. The radial runout error of the bearing does not exceed 0.01mm, ensuring the smooth rotation of the driven wheel 3 and reducing electrode wire tension fluctuations. The driven wheel 3 is connected to the outer shell 1 through the high-precision bearing installed on the central shaft. When the driving wheel drives the electrode wire to move, the driven wheel rotates accordingly. The radial runout error of the high-precision bearing does not exceed 0.01mm, ensuring the smooth rotation of the driven wheel 3, reducing electrode wire tension fluctuations, ensuring machining accuracy and consistency, and reducing electrode wire wear.

[0030] Specifically, the tension wheel 4 is made of lightweight and wear-resistant ceramic material with a surface roughness of no more than Ra0.4μm, which reduces its own weight, extends its service life, and reduces wear on the electrode wire. The electrode wire passes around the tension wheel 4, and when the tension of the electrode wire changes, the tension wheel adjusts its position through the telescopic tension arm 5, while the displacement sensor 9 monitors its displacement in real time. The use of lightweight and wear-resistant ceramic material with a surface roughness of no more than Ra0.4μm reduces its own weight, extends its service life, and reduces wear on the electrode wire. The displacement sensor 9 has a measurement accuracy of 0.01mm, providing real-time and accurate feedback on the tension status of the electrode wire.

[0031] Specifically, the telescopic tension arm 5 includes a telescopic rod and a return spring. The telescopic rod is made of stainless steel with a hardness of HRC30-35, and the return spring has an elastic coefficient of 5-10 N / mm. When the electrode wire tension changes, the telescopic tension arm 5 can flexibly extend and retract to provide corresponding tension compensation. When the electrode wire tension changes, the telescopic rod extends and retracts under the action of the return spring, driving the tension wheel 4 to move, thereby achieving tension compensation. The telescopic rod is made of stainless steel with a hardness of HRC30-35, and the return spring has an elastic coefficient of 5-10 N / mm, allowing for flexible extension and retraction, timely tension compensation for the electrode wire, maintaining tension stability, and ensuring processing accuracy and electrode wire lifespan.

[0032] Specifically, the piston rod 6 has a telescopic stroke of 10-20mm and its surface is chrome-plated with a chrome layer thickness of 0.02-0.05mm to improve the wear resistance and corrosion resistance of the piston rod 6 and ensure its smooth telescopic movement. During equipment operation, the piston rod 6 telescopically moves as needed, possibly to adjust the overall structure of the roller assembly or tension-related parameters. The 10-20mm telescopic stroke and 0.02-0.05mm chrome plating improve wear resistance and corrosion resistance, ensure smooth telescopic movement, extend service life, and reduce equipment maintenance costs.

[0033] Specifically, the inner wall of the threaded sleeve 7 is provided with a guide keyway, and the threaded adjusting rod 8 is provided with a guide key that mates with the guide keyway. The guide keyway has a depth of 2-3 mm and a width of 5-6 mm, ensuring that the threaded adjusting rod 8 does not circumferentially shift when rotating within the threaded sleeve 7, thus guaranteeing adjustment accuracy. By rotating the threaded adjusting rod 8 within the threaded sleeve 7, the threaded adjusting rod 8 will not circumferentially shift due to the engagement of the guide keyway and the guide key, achieving precise linear adjustment. The guide keyway has a depth of 2-3 mm and a width of 5-6 mm, ensuring adjustment accuracy and meeting the requirements of high-precision machining for electrode wire tension adjustment.

[0034] Specifically, a displacement sensor 9 is also installed on the tension wheel 4. The displacement sensor 9 is a high-precision linear displacement sensor with a measurement accuracy of up to 0.01mm. It can accurately monitor the displacement changes of the tension wheel 4 in real time, and thus provide feedback on the real-time status of the electrode wire tension. The displacement sensor 9 monitors the displacement changes of the tension wheel 4 in real time and feeds the data back to the control system. The high-precision linear displacement sensor has a measurement accuracy of 0.01mm, which provides an accurate basis for operators to adjust the processing parameters in a timely manner and ensures stable processing quality.

[0035] Specifically, the diameter ratio of the driving wheel 2, driven wheel 3, and tension wheel 4 is 2:1.5:1. This optimized diameter ratio effectively balances the tension distribution of the electrode wire on the roller assembly, improving the stability of the electrode wire's operation. The electrode wire runs on the driving wheel 2, driven wheel 3, and tension wheel 4 with a diameter ratio of 2:1.5:1. This optimized diameter ratio effectively balances the tension distribution of the electrode wire on the roller assembly, ensuring uniform force on the electrode wire, improving operational stability and machining accuracy, and reducing localized excessive wear.

[0036] The working process of this utility model is as follows: When using the adaptive roller assembly for electrode wire tension, firstly, fix the left and right outer shells 1 in the corresponding positions of the equipment. By rotating the threaded adjusting rod 8, it rotates within the threaded sleeve 7. Utilizing the guide keyway and guide key, the initial positions of each component of the roller assembly are precisely adjusted to ensure adjustment accuracy. After adjustment, the piston rod 6 is placed in a suitable extension / retraction state. Its chrome-plated surface ensures smooth extension and retraction. The electrode wire is sequentially passed around the driving wheel 2, driven wheel 3, and tension wheel 4. The spiral groove anti-slip texture on the surface of the driving wheel 2 is in close contact with the electrode wire, providing sufficient friction. The driven wheel 3 rotates smoothly through a high-precision bearing on the central shaft, reducing electrode wire tension fluctuations.

[0037] During equipment operation, when the electrode wire tension changes, the retractable tension arm 5 on the outside of the tension wheel 4 begins to work. The telescopic rod extends and retracts under the action of the return spring, driving the tension wheel 4 to move for tension compensation. At the same time, the displacement sensor 9 on the tension wheel 4 monitors the displacement changes of the tension wheel 4 in real time and feeds the data back to the control system for further adjustments.

[0038] The driving wheel 2 drives the electrode wire to move continuously. Since the diameter ratio of the driving wheel 2, driven wheel 3, and tension wheel 4 is 2:1.5:1, the tension distribution of the electrode wire on the roller assembly is effectively balanced, ensuring stable operation of the electrode wire. During this process, the piston rod 6 can readjust its extension and retraction state as needed to fine-tune the roller assembly structure; the displacement sensor 9 continuously monitors to ensure that the electrode wire tension is always in an ideal state until processing is completed.

[0039] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A wire tension adaptive roller assembly for a medium-speed wire electrode, comprising an outer housing (1) located on the left and right sides for mounting, characterized in that: Between the outer shells (1), there are respectively a driving wheel (2) located on the upper front side, a driven wheel (3) located on the upper rear side, and a tension wheel (4) located below the driving wheel (2) and the driven wheel (3). A telescopic tension arm (5) is connected to the outside of the tension wheel (4). A telescopic piston rod (6) is provided on the front and rear sides at the upper position between the left and right outer shells (1). A threaded sleeve (7) and a threaded adjusting rod (8) are respectively provided at the middle position between the left and right outer shells (1). The left and right sides of the threaded adjusting rod (8) are threadedly connected to the inside of the threaded sleeve (7).

2. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The surface of the drive wheel (2) is provided with anti-slip texture, which is a spiral groove with a depth of 0.5-1mm and a pitch of 2-3mm, in order to increase the friction between the drive wheel and the electrode wire and prevent the electrode wire from slipping.

3. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: A high-precision bearing is installed between the central axis of the driven wheel (3) and the outer shell (1). The radial runout error of the bearing does not exceed 0.01mm, ensuring the smooth rotation of the driven wheel (3) and reducing the tension fluctuation of the electrode wire.

4. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The tension wheel (4) is made of lightweight and wear-resistant ceramic material with a surface roughness of no more than Ra0.4μm, which reduces its own weight, extends its service life, and reduces wear on the electrode wire.

5. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The retractable tension arm (5) includes a telescopic rod and a return spring. The telescopic rod is made of stainless steel with a hardness of HRC30-35. The spring constant is 5-10 N / mm. When the electrode wire tension changes, the retractable tension arm (5) can flexibly extend and retract and provide corresponding tension compensation.

6. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The piston rod (6) has a telescopic stroke of 10-20mm and its surface is chrome-plated with a chrome plating layer thickness of 0.02-0.05mm, which improves the wear resistance and corrosion resistance of the piston rod (6) and ensures its smooth telescopic movement.

7. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The inner wall of the threaded sleeve (7) is provided with a guide keyway, and the threaded adjusting rod (8) is provided with a guide key that cooperates with the guide keyway. The depth of the guide keyway is 2-3mm and the width is 5-6mm, which ensures that the threaded adjusting rod (8) will not be circumferentially offset when it rotates in the threaded sleeve (7), thus ensuring the adjustment accuracy.

8. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The tension wheel (4) is also equipped with a displacement sensor (9), which is a high-precision linear displacement sensor with a measurement accuracy of up to 0.01 mm. It can monitor the displacement change of the tension wheel (4) in real time and thus provide feedback on the real-time state of the electrode wire tension.

9. The adaptive roller assembly for wire tension of the wire electrode according to claim 1, characterized in that: The diameter ratio of the driving wheel (2), driven wheel (3) and tension wheel (4) is 2:1.5:

1. The optimized diameter ratio can effectively balance the tension distribution of the electrode wire on the roller assembly and improve the stability of the electrode wire operation.

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