EDM Pump Control Using Synchronized Inverter Flow Rates
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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 frequencies based on the flow rates of the jetting pump to optimize energy usage and prevent fluid shortages, ensuring stable machining operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the feeding pump and circulation pump operate at utility frequency with high flow rates, then the work fluid is supplied充足 to the work tank and clean fluid tank, 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 unit dynamically adjusts the rotation speeds of these pumps based on real-time machining conditions and fluid level feedback, replacing fixed utility frequency operation with adaptive speed control to optimize energy consumption while maintaining reliable work fluid supply.
Solution Approach 2:
The patent implements feedback control through liquid level detectors that monitor the work tank and clean fluid tank levels. The control unit receives this feedback and adjusts the feeding pump and circulation pump speeds accordingly, ensuring adequate fluid supply while minimizing energy waste from excessive flow rates.
2Use of energy by moving object
If the jetting pump flow rate is reduced for energy conservation, then energy consumption decreases, but the liquid level in the work tank may fall below the lower limit
Solution Approach 1:
The control unit continuously monitors the work tank liquid level through a liquid level detector and adjusts the jetting pump flow rate based on this feedback. When the liquid level approaches the lower limit, the system increases the jetting pump speed to maintain adequate levels, while allowing energy-saving reduced flow rates during periods of sufficient fluid supply.
Solution Approach 2:
The system automatically balances energy conservation and fluid level maintenance through the control unit's autonomous decision-making. The control unit integrates information from liquid level detectors and machining condition inputs to self-adjust pump operations without manual intervention, optimizing the trade-off between energy consumption and fluid supply reliability.
3Use of energy by moving object
If individual pumps are controlled by inverters independently, then energy conservation becomes possible, but adverse effects on electric discharge machining quality may occur
Solution Approach 1:
The patent merges the control of multiple pumps under a single integrated control unit that coordinates the jetting pump, feeding pump, and circulation pump based on overall machining conditions rather than independent control. This unified approach ensures that energy conservation measures do not compromise machining quality, as the system adjusts all pumps in coordination to maintain optimal work fluid conditions in the work tank.
Solution Approach 2:
The control unit dynamically adjusts multiple parameters including the rotation speeds of all three pumps, jetting pressure, and flow rates based on machining conditions. By coordinating these parameter changes across the entire pump system rather than independently, the system achieves energy conservation while maintaining the work fluid conditions necessary for high-quality electric discharge machining.
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 maintaining machining quality by synchronizing pump flow rates, preventing fluid level issues and temperature increases, thereby enhancing the efficiency and reliability of electric discharge machining.
Implementation Method 1
a pump controller for performing inverter control of the jetting pump, the feeding pump, and the circulation pump
Implementation Method 2
The electric discharge machine is configured to be able to jet the work fluid from a jetting nozzle toward the gap during machining
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
Implementation Method 4
The electric discharge machine applies a machining voltage to a gap to generate a discharge in the gap while relatively moving the electrode and the workpiece, and machines the workpiece into a desired shape using an electronic discharge energy
Data Source
AI summary
An electric discharge machine and an electric discharge machining method for the electric discharge machine are provided. The electric discharge machine includes a circulation pump for pressure-feeding a work fluid in a dirty fluid tank to a filter; a jetting pump for pressure-feeding the work fluid in the clean fluid tank to a jetting nozzle; a feeding pump for pressure-feeding the work fluid in the clean fluid tank to the work tank; and a pump controller for inverter-controlling the circulation pump, the jetting pump, and the feeding pump. The pump controller includes a jetting pump controller configured to set an inverter frequency of the jetting pump, and a feeding pump controller 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.