EDM Workpiece Weight Calculation via Machining Liquid Displacement
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Solution Overview
Problem
Conventional electric discharge machining systems face challenges in accurately calculating the weight of workpieces and jigs without labor-intensive manual measurements, leading to potential pitch errors and inefficiencies, especially when dealing with varying weights or different materials.
Innovation Solution
The system automatically calculates the weight of workpieces and jigs by measuring the volume of machining liquid in a tank, using a liquid level sensor and flowmeter to determine the liquid amount and volume changes, and stores densities for precise weight calculations, eliminating the need for external scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large measuring device is prepared to measure the weight of a heavy workpiece, then the weight measurement capability is improved, but the device complexity and labor requirement increase
Solution Approach 1:
The patent introduces machining liquid as an intermediary medium to indirectly measure the weight of heavy workpieces. Instead of directly measuring the workpiece weight with a large scale, the system measures the volume of machining liquid displaced by the workpiece and calculates weight from this volume, thereby avoiding the need for large measuring devices
Solution Approach 2:
The patent replaces the mechanical weighing system (large scale) with a fluid-based measurement system. By measuring the volume of machining liquid and using density relationships, the system substitutes direct mechanical weight measurement with an indirect fluid displacement method, eliminating the need for large mechanical measuring devices
2Measurement precision
If manual weight measurement and input operations are performed for each workpiece, then measurement accuracy is improved, but productivity decreases
Solution Approach 1:
The system performs self-service by automatically calculating workpiece weight through volume measurement of machining liquid. The controller automatically obtains volume data, retrieves density information from storage, and computes weight without requiring manual measurement or data input operations, thereby maintaining measurement accuracy while significantly improving productivity
Solution Approach 2:
The system establishes a feedback loop where the controller continuously monitors machining liquid volume, automatically updates weight calculations, and uses this information for pitch error correction. This automated feedback mechanism eliminates manual intervention while maintaining measurement precision and improving operational efficiency
3Manufacturing precision
If pitch error correction is performed using previously measured workpiece weights, then correction accuracy is improved, but the system cannot adapt to workpieces with different weights
Solution Approach 1:
The system transitions from a static correction approach (using fixed correction values for specific weights) to a dynamic correction approach. The controller dynamically calculates pitch error correction amounts based on the actual measured volume of machining liquid and the specific density of the current workpiece, enabling accurate correction for any workpiece weight while maintaining high manufacturing precision
4Measurement precision
If individual weight measurement of workpieces and jigs is performed, then measurement accuracy is improved, but labor requirement increases
Solution Approach 1:
The system merges the measurement of workpiece and jig weights into a single automated process. By measuring the total volume of machining liquid displaced by both the jig and workpiece together, and automatically calculating their combined weight using stored density information, the system eliminates the need for separate manual measurement operations, thereby maintaining measurement accuracy while significantly improving ease of operation
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 method allows for efficient, automated weight calculation of workpieces and jigs, reducing labor and measurement errors, enhancing productivity and precision in pitch error correction, and applying to various electric discharge machines.
Implementation Method 1
measuring the volume of machining liquid in a tank, using a liquid level sensor and flowmeter to determine the liquid amount and volume changes
Implementation Method 2
a volume of the workpiece is obtained from a difference between an amount of machining liquid reaching the predetermined water level in a state where the previously calculated workpiece is not placed on the table and an amount of machining liquid which is supplied in a state where the workpiece is placed on the table
Data Source
AI summary
A machining liquid is supplied to a predetermined level when a workpiece is on a table. A volume of the workpiece is obtained from a difference between the machining liquid amount at the predetermined level when a previous workpiece is not on the table, and the machining liquid amount when the workpiece is on the table. A weight of the workpiece is obtained from the obtained volume and a previously stored density of the workpiece. A weight of a mounting jig is obtained in the same procedure. A total volume of the jig and workpiece is obtained when the jig is on the table and the workpiece is fixed to the jig. The volume of the workpiece is obtained by a difference with respect to the volume of the jig. The weight of the workpiece fixed to the jig is obtained from the obtained volume and the previously stored density.