Electrode Holder Control Circuit for EDM Roller Bearing Dust Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electrical discharge machines using ultrasonic motors and roller bearings, the increase in sliding resistance due to dust production between rolling elements and the surrounding path leads to decreased movement speed of the electrode holder, resulting in longer machining times.
Innovation Solution
The electrical discharge machine incorporates a control circuit that detects abnormal resistance and moves the electrode holder by a distance equivalent to the largest roller element's roll and rotation, without sliding, to disperse dust and reduce sliding resistance, thereby maintaining efficient movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the electrode holder is moved by an ultrasonic motor using a roller bearing for long periods at extremely short unit distances, then positioning precision is improved, but sliding resistance increases and movement speed decreases
Solution Approach 1:
The control circuit periodically performs a maintenance movement operation where the electrode holder is moved by a distance equivalent to when the largest roller element rolls and rotates once without sliding. This periodic action prevents dust accumulation and maintains low sliding resistance, allowing the system to sustain both high positioning precision and movement speed over long operational periods
Solution Approach 2:
The system temporarily discards the extremely short unit distance movement mode by performing a larger maintenance movement operation. This recovery operation clears dust from the roller bearing path, restoring optimal conditions for precise and fast movement
2Measurement precision
If the electrode holder is moved by an ultrasonic motor using a roller bearing for long periods at extremely short unit distances, then positioning precision is improved, but machining time increases
Solution Approach 1:
The control circuit implements periodic maintenance movements at scheduled intervals during machining operations. These brief periodic actions prevent dust accumulation that would otherwise cause progressive speed reduction and extended machining times, thereby maintaining both precision and efficiency over long operational periods
Solution Approach 2:
By performing periodic maintenance movements, the system maintains continuous optimal operating conditions for the roller bearing. This ensures that the electrode holder can continuously perform precise movements at maximum speed without interruptions or slowdowns due to dust accumulation
3Measurement precision
If the electrode holder is moved by an ultrasonic motor using a roller bearing, then movement control at extremely short unit distances is improved, but sliding resistance increases due to dust production
Solution Approach 1:
The control circuit utilizes the periodic maintenance movement operation to convert the harmful dust accumulation into a beneficial clearing action. By moving the electrode holder by a distance equivalent to one full roller rotation, the system actively removes dust from the bearing path, transforming the dust problem into an opportunity for self-cleaning and maintenance
Solution Approach 2:
The system temporarily discards the precise short-distance movement mode to perform a larger maintenance movement that clears dust. This recovery operation restores the roller bearing to optimal condition, eliminating the harmful dust effect and enabling continued precise movement control
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
This solution effectively suppresses the increase in sliding resistance and maintains the electrode holder's movement speed, reducing the time required for machining by ensuring smooth operation of the roller bearing.
Implementation Method 1
The ultrasonic motor has a fingertip that comes into contact with the electrode holder, and moves the electrode holder in a driving direction by moving the fingertip in an annular manner at an ultrasonic-range frequency
Implementation Method 2
An electrical discharge machine applies a voltage between an electrode and a workpiece, thereby generating electrical discharge. The workpiece is melted by the electrical discharge and machined
Data Source
AI summary
In an electrical discharge machine that applies a voltage between an electrode and a workpiece to generate electrical discharge, an electrode holder holds the electrode. An ultrasonic motor has a fingertip that comes into contact with electrode holder, and moves electrode holder in a driving direction by moving the fingertip in an annular manner at an ultrasonic-range frequency. A roller bearing guides the movement of the electrode holder in the driving direction. A control circuit controls a position of the electrode in the driving direction by driving the ultrasonic motor, and moves the electrode holder based on an abnormality occurring in resistance against the movement of the electrode holder in the driving direction such that the electrode holder is moved by a movement distance equivalent to when the largest roller element among a plurality of roller elements of the roller bearing rolls and rotates once without sliding or longer.