Wire-cut EDM Liquid Level Adjustment for Automatic Threading
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Solution Overview
Problem
Wire-cut EDM machines face inefficiencies in automatic wire threading for workpieces with varying plate thickness, as the distance from the nozzle to the workpiece surface changes, leading to reduced success rates and longer threading times due to varying wire-threading conditions.
Innovation Solution
A wire-cut EDM machine with a control device that adjusts the machining fluid's liquid level based on the workpiece's shape and wire electrode rigidity, using shape information acquisition, wire-threading position information, and liquid level position adjustment units to optimize the fluid level during automatic wire threading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire threading is performed at the position of break occurrence to reduce threading time, then productivity is improved, but manufacturing precision deteriorates due to varying wire-threading conditions on workpieces with varying plate thickness
Solution Approach 1:
The liquid level position adjustment unit dynamically adjusts the liquid level position based on the workpiece shape information and wire-threading position to maintain optimal threading conditions. This dynamic adjustment ensures the wire electrode is exposed to air during threading while keeping the liquid level adapted to the local workpiece height, resolving the contradiction between fast threading and high success rate.
Solution Approach 2:
The system changes the liquid level position parameter according to the workpiece shape and threading location. By adjusting this parameter dynamically, the system maintains consistent wire-threading conditions regardless of varying plate thickness, thereby preserving manufacturing precision while improving productivity.
2Manufacturing precision
If the liquid level position is adjusted to improve wire threading success rate, then manufacturing precision is improved, but device complexity increases due to additional control mechanisms
Solution Approach 1:
The control device integrates multiple functions including shape information acquisition, wire-threading position determination, and liquid level position adjustment into a single multi-functional system. This universal control unit manages all aspects of the wire-cut EDM process, reducing overall device complexity while maintaining high manufacturing precision.
Solution Approach 2:
The system uses feedback from workpiece shape information and wire-threading position data to automatically adjust the liquid level position. This closed-loop feedback mechanism ensures optimal threading conditions without requiring complex manual control, balancing manufacturing precision with manageable device complexity.
3Manufacturing precision
If the liquid level position is adjusted in accordance with workpiece shape, then manufacturing precision is improved, but loss of time increases due to adjustment operations
Solution Approach 1:
The system performs preliminary acquisition of workpiece shape information and wire-threading position data before the actual wire threading operation. The liquid level position is adjusted in advance based on this pre-acquired information, ensuring optimal conditions are ready before threading begins, thereby minimizing actual threading time loss.
Solution Approach 2:
The automatic adjustment of liquid level position based on workpiece shape information ensures continuous optimal conditions during wire threading. By maintaining the liquid level in the correct position throughout the threading process, the system eliminates interruptions and maintains continuous productive action, reducing overall time loss.
Data Source
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AI summary
A wire-cut EDM machine in which the position of the liquid level of machining fluid is adjusted at the time of automatic wire threading includes a shape information acquisition unit for acquiring information on the shape of an object to be machined, a wire-threading position information acquisition unit for acquiring information on a wire-threading position of a wire electrode based on relative positions of upper and lower wire guides, and a liquid level position adjustment unit for acquiring the height of the object to be machined in the vicinity of the wire-threading position based on the information on the shape of the object to be machined and adjusting the position of the liquid level of the machining fluid at the time of automatic wire threading.