Multi-wire EDM Power Supply Resistance Distribution
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Solution Overview
Problem
In multi-wire electrical discharge machining systems, when electric discharge does not occur uniformly between multiple wires and a workpiece, surplus machining current is supplied to the wires where discharge occurs, leading to inefficiencies and potential wire breakage.
Innovation Solution
A system where the resistance between the power supply device and the power feed contact is smaller than the resistance between the power feed contact and the electrical discharge portion, allowing for collective power supply to multiple wires, ensuring even current distribution and preventing excessive current to specific wires during non-uniform discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power is collectively supplied to multiple wires through a single power feed contact, then device complexity is reduced and productivity is improved, but when electric discharge does not occur uniformly, surplus machining current is supplied to specific wires causing wire breakage and reducing reliability
Solution Approach 1:
The invention changes the electrical parameter (resistance) of the power supply path by making the resistance between the power supply device and power feed contact smaller than the resistance between the power feed contact and electrical discharge portion. This parameter change ensures that when electric discharge does not occur uniformly across all wires, the surplus current flows through the lower resistance path back to the power supply device rather than concentrating on specific wires, thereby preventing wire breakage while maintaining the simple collective power supply structure
Solution Approach 2:
The invention provides a protective mechanism in advance by designing the resistance distribution such that the path from power supply device to power feed contact has smaller resistance than the path from power feed contact to electrical discharge portion. This beforehand cushioning ensures that under abnormal conditions (non-uniform electric discharge), the system automatically directs surplus current away from the wires through the pre-designed lower resistance return path, preventing wire breakage before it occurs
2Reliability
If individual power supply is used for each wire, then current distribution is controlled precisely and wire reliability is improved, but device complexity increases and machining efficiency decreases
Solution Approach 1:
The invention merges the power supply structure by using a single power feed contact to collectively supply power to multiple wires, simplifying the device structure.同时，通过设计电阻分布（电源装置到供电接触的电阻小于供电接触到放电部分的电阻），在合并供电的同时实现了电流的控制和保护功能
3Productivity
If collective power supply is used to multiple wires, then productivity is improved by maintaining machining speed, but when discharge is non-uniform, excessive current to specific wires causes wire breakage
Solution Approach 1:
The invention changes the resistance parameter distribution in the electrical circuit to protect wire stability while maintaining collective power supply for high productivity. By making the resistance from power supply device to power feed contact smaller than from power feed contact to electrical discharge portion, the system ensures that surplus current during non-uniform discharge flows through the lower resistance return path, preventing wire breakage and maintaining reliable operation at high machining speeds
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 prevents excessive machining current from being supplied to wires where discharge occurs, maintaining efficient machining speed and reducing wire breakage, even when discharge is not uniform across all wires, and allows for equivalent machining speed as individual wire power supply.
Implementation Method 1
a power feed contact configured to collectively come into contact with the plurality of the traveling wires, and an electrical discharge portion configured to electrically discharge to the workpiece a machining power supply in which the plurality of the traveling wires comes into contact with the power feed contact to collectively supply power
Implementation Method 2
an electrical discharge portion configured to electrically discharge to the workpiece a machining power supply
Data Source
AI summary
A multi-wire electrical discharge machining system for slicing a workpiece into a thin leaf at intervals of a plurality of wires arranged together causes the wires arranged together to travel in the same direction and includes a power feed contact configured to collectively comes into contact with the traveling wires, a machining power supply portion configured to supply a machining power supply to the power feed contact, and an electrical discharge portion configured to electrically discharge a machining power supply in which the traveling wires comes into contact with the power feed contact to collectively supply power to the traveling wires to the workpiece, in which a resistance between the machining power supply portion and the power feed contact is smaller than a resistance between the power feed contact and the electrical discharge portion.