Electrical Discharge Machine Wire Electrode Angling Mechanism
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Solution Overview
Problem
Conventional electrical discharge machines with wire electrodes have complex configurations that increase manufacturing costs and failure rates due to the need for multiple movable parts and complex liquid-proof measures to angle the wire electrode, which complicates the alignment of the wire electrode with guide rollers and dies.
Innovation Solution
The electrical discharge machine incorporates a lower support part on a tilt shaft and an upper support part on a forward/backward shaft, allowing both to tilt in a coordinated plane, with guide rollers that rotate within this plane to maintain wire electrode tension and prevent rubbing, and a liquid supply system to reduce friction, eliminating the need for complex liquid-proof measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the upper support part and lower support part are displaced to angle the wire electrode, then the wire electrode can be angled to cut non-vertical surfaces, but the wire electrode is rubbed excessively against the dies
Solution Approach 1:
Guide rollers are introduced as intermediary components between the wire electrode and the dies. These guide rollers redirect the wire electrode path, allowing the wire to enter and exit the dies at optimal angles while the support parts can be displaced to angle the wire electrode for cutting non-vertical surfaces. This intermediary mechanism prevents excessive rubbing between the wire electrode and dies.
2Manufacturing precision
If tilting means or rotating means is provided to adjust the wire electrode angle, then the wire electrode can be precisely angled, but the device complexity increases
Solution Approach 1:
The support parts are made movable and displaceable rather than fixed, allowing dynamic adjustment of the wire electrode angle. The upper and lower support parts can be independently displaced to achieve the desired wire electrode angle for different cutting applications, providing precision without requiring complex tilting or rotating mechanisms.
Solution Approach 2:
The support system is divided into separate upper and lower support parts that can be independently positioned and adjusted. This segmentation allows each support part to be optimized for its specific function and adjusted independently to achieve precise wire electrode angling without requiring the entire assembly to be complex.
3Manufacturing precision
If multiple movable parts are used to angle the wire electrode, then the wire electrode alignment is improved, but the manufacturing cost and failure rate increase
Solution Approach 1:
The guide rollers serve multiple functions: they redirect the wire electrode path, support the wire electrode, and enable the support parts to be displaced for angling the wire electrode. This multi-functionality reduces the need for additional specialized components, lowering manufacturing complexity and cost while maintaining precise alignment capability.
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 configuration simplifies the device, reduces manufacturing costs, and minimizes failure rates by allowing easy angling of the wire electrode without precise control of multiple moving parts, while maintaining effective liquid management and reducing friction.
Implementation Method 1
the workpiece is chipped away by electrical discharge generated between the wire electrode and the workpiece
Implementation Method 2
a liquid supply system to reduce friction
Data Source
AI summary
An electrical discharge machine including a lower support part (2) provided to a tilt shaft (4) rotatable and extending horizontally and an upper support part (3) provided to a forward/backward shaft (5) extending parallel to the tilt shaft (4) from a support column (42) provided vertically to the tilt shaft (4) and movable forward and backward in the extending direction. The lower support part (2) includes a lower guide roller (21) that rotates in a tilting plane in which the tilt shaft (4), the support column (42), and the forward/backward shaft (5) lie, the upper support part (5) includes an upper guide roller (31) that rotates in the tilting plane in which the tilt shaft (4), the support column (42), and the forward/backward shaft (5) lie, and a wire electrode (1) is suspended around the upper guide roller (31) and the lower guide roller (21).