EDM Pump Inverter Coordination for Stable Work Fluid Supply
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Solution Overview
Problem
Electric discharge machines face energy inefficiencies due to independent control of pumps, leading to potential machining quality issues and increased energy consumption, particularly when the flow rates of the feeding and circulation pumps exceed necessary levels, causing temperature rises and fluid level concerns.
Innovation Solution
Implementing a pump controller that performs comprehensive inverter control across the jetting, feeding, and circulation pumps, adjusting their flow rates in sync with each other to optimize energy usage without compromising machining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the feeding pump and circulation pump operate at utility frequency with high flow rates, then the work fluid supply is sufficient, but energy consumption increases and work fluid temperature rises
Solution Approach 1:
The patent applies dynamic control by equipping the feeding pump and circulation pump with inverters that allow variable speed operation. The control device dynamically adjusts the rotation speeds of these pumps based on real-time machining conditions, replacing the conventional fixed utility frequency operation. This enables the system to operate at optimal speeds rather than always at maximum capacity, reducing energy consumption while maintaining sufficient work fluid supply reliability.
Solution Approach 2:
The control device implements feedback control by continuously monitoring machining conditions and adjusting the pump speeds accordingly. The system receives information about the machining state and uses this feedback to optimize the rotation speeds of the feeding and circulation pumps, ensuring energy efficiency is improved without compromising the reliability of work fluid supply to the work tank.
2Use of energy by moving object
If the jetting pump flow rate is reduced, then energy consumption decreases, but the liquid level in the work tank may fall below the lower limit
Solution Approach 1:
The patent merges the control of the jetting pump with the feeding and circulation pumps through a unified control device. By coordinating the operation of all three pumps, the system ensures that when the jetting pump flow rate is reduced for energy efficiency, the feeding and circulation pumps adjust their speeds to compensate, maintaining the liquid level in the work tank above the lower limit and preventing adverse effects on machining quality.
Solution Approach 2:
The control device uses feedback mechanisms to monitor the liquid level in the work tank and adjusts the pump speeds accordingly. When the jetting pump flow rate is reduced, the feedback system detects potential liquid level drops and adjusts the feeding and circulation pumps to maintain adequate levels, ensuring machining quality is preserved while still achieving energy savings.
3Use of energy by moving object
If each pump is individually controlled by an inverter, then energy efficiency improves, but adverse effects on electric discharge machining may occur
Solution Approach 1:
The patent merges the individual inverter controls into a unified control system that coordinates all three pumps (jetting, feeding, and circulation) simultaneously. This integrated approach ensures that energy efficiency is improved through inverter control while the coordinated operation prevents adverse effects on machining stability that would result from independent pump control adjustments.
Solution Approach 2:
The control device implements comprehensive feedback control that monitors the overall machining process and adjusts all pump speeds in coordination. This feedback mechanism ensures that individual pump adjustments for energy efficiency do not create instability in the electric discharge machining process, maintaining reliability while achieving energy savings.
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 approach reduces energy consumption while preventing adverse effects on electric discharge machining by ensuring proper fluid levels and flow rates, maintaining machining quality and efficiency.
Implementation Method 1
a pump controller 8 that performs inverter control of the jetting pump 5, the feeding pump 6, and the circulation pump 7
Implementation Method 2
a jetting nozzle 51 for jetting the work fluid F toward a gap formed by the workpiece W and a tool electrode
Implementation Method 3
The circulation pump supplies dirty work fluid stored in the dirty fluid tank to a filter. The filter removes machining chips and sludge from the work fluid and discharges it into the clean fluid tank.
Data Source
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AI summary
An electric discharge machine and an electric discharge machining method thereof are provided. The electric discharge machine includes a circulation pump (7) for pressure-feeding a work fluid (F) in a dirty fluid tank (3) to a filter (71); a jetting pump (5) for pressure-feeding the work fluid in the clean fluid tank (4) to a jetting nozzle (51); a feeding pump (6) for pressure-feeding the work fluid in the clean fluid tank to the work tank (2); and a pump controller (8) for inverter-controlling the circulation pump, the jetting pump, and the feeding pump. The pump controller includes a jetting pump controller (85) configured to set an inverter frequency of the jetting pump, and a feeding pump controller (86) configured to acquire the flow rate of the inverter-controlled jetting pump and set an inverter frequency of the feeding pump based on the flow rate of the inverter-controlled jetting pump.