Rotating Spindle Current Transfer via Conductive Threads
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Solution Overview
Problem
Existing wire EDM machines face issues with carbon brushes used for eroding current transfer, leading to abrasion, contamination, and reduced service life, which affect the reliability and maintenance costs of the machines.
Innovation Solution
A drive device with a circular ring cylinder current transfer device featuring radially arranged electrically conductive threads that make contact with the rotating spindle or workpiece, eliminating the need for carbon brushes and ensuring stable functionality and extended service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon brushes are used for current transfer to the rotating spindle, then electrical current can be supplied to the workpiece, but the brushes experience abrasion and contamination leading to reduced service life and increased maintenance costs
Solution Approach 1:
The patent replaces the mechanical contact system of carbon brushes with an electrical field-based current transfer mechanism. The conductive threads create an electrical field that transfers current without physical contact, eliminating mechanical wear and contamination. This substitution of mechanical contact with field-based interaction directly resolves the contradiction between current transfer capability and brush degradation.
Solution Approach 2:
The conductive threads act as an intermediary between the power source and the rotating spindle. Instead of direct mechanical contact through brushes, the threads create an electrical field that mediates the current transfer process, allowing current to reach the workpiece without the intermediary carbon brushes experiencing wear and contamination.
2Use of energy by moving object
If carbon brushes are used for current transfer, then power can be transmitted to the rotating workpiece, but dirt and abrasion byproducts contaminate the machine environment
Solution Approach 1:
The patent eliminates the mechanical carbon brush system that generates contamination through abrasion. By using conductive threads that create an electrical field for current transfer, the system removes the source of dirt and contamination while maintaining the essential function of power transmission to the rotating workpiece.
3Productivity
If carbon brushes are used for current supply, then electrical discharge machining can be performed, but maintenance costs increase due to brush wear and filter replacement
Solution Approach 1:
The patent replaces the wear-prone mechanical carbon brush system with a durable electrical field-based current transfer using conductive threads. This elimination of mechanical contact components removes the need for periodic brush replacement and reduces filter maintenance, thereby lowering maintenance costs while preserving the erosive machining capability.
Solution Approach 2:
The patent eliminates the need for disposable carbon brushes that require periodic replacement. The conductive threads provide a long-lasting current transfer solution that does not degrade through use, removing the recurring maintenance cycle of brush replacement and associated costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reliable and long-lasting current transfer method that prevents abrasion and contamination, ensuring stable functionality and reducing maintenance costs by using electrically conductive microfibers for efficient power transmission in wire EDM machines.
Implementation Method 1
the inner lateral surface has electrically conductive threads running radially for the current supply, and the current transfer device is arranged in such a way that the distal ends of the electrically conductive threads make electrical contact with the rotating or statically indexed workpiece
Data Source
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AI summary
The invention relates to a drive device (1) for a wire erosion machine with a rotating indexing spindle (3) driven by a motor (2) and a current transfer device (10) for transferring current to a rotating or indexed workpiece (4) for erosive machining or a statically indexed cutting task, wherein the rotating indexing spindle (3) has a workpiece holder (5) for holding the workpiece (4) to be machined. According to the invention, the current transfer device (10) is constructed as at least one sector (10a, 10b, 10c, 10d) of an annular cylinder in which the inner surface (11) has radially running electrically conducting filaments (12) to supply the current and the current transfer device (10) is arranged in such a manner that the distal ends of the electrically conducting filaments (12) make an electrical contact with the rotating and indexing spindle (3).