Threshold-Based Data Collection for Electric Discharge Machines
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Solution Overview
Problem
Existing data collection systems for electric discharge machines face challenges in storing multiple types of monitoring information due to limited storage capacity in numerical controllers, leading to increased costs and potential network communication issues during long machining times.
Innovation Solution
A data collection system where an electric discharge machine detects machining conditions at predetermined intervals or distance traveled, determines if these conditions exceed thresholds, and stores only the exceeding data, which is then transmitted to a computer after machining, minimizing storage needs and avoiding continuous network data transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If monitoring information is stored at predetermined time intervals in the numerical controller, then data volume becomes large, but storage capacity is limited
Solution Approach 1:
The patent changes the storage parameter from continuous time-interval recording to threshold-based selective recording. Instead of storing data at fixed time intervals, the system only stores data when specific parameters (monitoring information) exceed predetermined thresholds, thereby reducing data volume while maintaining measurement precision for critical events
Solution Approach 2:
The patent extracts only the necessary monitoring information that exceeds thresholds from the continuous data stream, rather than storing all recorded data. This selective extraction reduces the quantity of stored data while preserving the essential information needed for quality assessment
2Quantity of substance
If a large-capacity storage device is mounted on the electric discharge machine, then various kinds of monitoring information can be stored, but costs of the electric discharge machine increase
Solution Approach 1:
The patent changes the storage approach by using threshold-based selective recording instead of continuous recording, which reduces the required storage capacity. This allows the system to store the same essential information with a smaller, more cost-effective storage device
Solution Approach 2:
The patent applies partial action by storing only the portion of monitoring information that exceeds thresholds rather than storing all monitoring data. This partial storage approach reduces the required storage capacity and associated costs while maintaining sufficient data for quality assessment
3Reliability
If monitoring information is continuously transferred over the network, then data can be stored in the computer, but communication load on the network increases or data may be lost due to network failure
Solution Approach 1:
The patent extracts only the essential monitoring information that exceeds thresholds for transmission over the network, rather than continuously transferring all monitoring data. This reduces network communication load and bandwidth requirements while maintaining data reliability
Solution Approach 2:
The patent uses periodic action by transmitting data only when threshold conditions are met rather than continuous transmission. This event-driven approach reduces network communication load and the risk of data loss while maintaining reliability for critical monitoring information
4Loss of information
If all monitoring information is stored in the numerical controller, then complete data is available, but storage capacity is exceeded for long machining times
Solution Approach 1:
The patent changes the storage strategy from storing all monitoring information to storing only information that exceeds predetermined thresholds. This parameter-based selective storage maintains completeness of essential information while reducing the quantity of stored data to fit within limited storage capacity
Solution Approach 2:
The patent applies local quality by differentiating between critical monitoring information (that exceeds thresholds) and non-critical information (within normal ranges). Only the critical portions are stored, giving different storage priorities to different parts of the monitoring data based on their importance
Data Source
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AI summary
In a data collection system for electric discharge machines, multiple electric discharge machines are connected with a computer over a data transmission path. Information on machining conditions of an electric discharge machine is stored in a storage unit of the electric discharge machine, and information sent from the electric discharge machine after completion of machining is collected by the computer. By minimizing monitoring information that is temporarily stored in the storage unit, various kinds of monitoring information can be stored without being affected by a network environment.