EDT Dielectric Fluid Collection System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical discharge machines for machining or applying a finish to workpieces face inefficiencies in fluid collection, leading to wastage and splashing, as fluid from the workpiece is not collected effectively.
Innovation Solution
The introduction of a separate drip bath positioned below the workpiece to collect falling dielectric fluid, which communicates with a return system that includes a spill bath and a pump to recycle the fluid back into the dielectric bath, along with a funnel or sloping surface to direct fluid into the drip bath and reduce splashing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a traditional dielectric bath is used to hold and replenish fluid, then the bath can be maintained and overflow can be caught and returned, but fluid falling from the workpiece is not collected efficiently, resulting in wastage and splashing
Solution Approach 1:
The fluid collection system is segmented into two distinct components: a spill bath positioned behind the dielectric bath to catch overflow, and a separate drip bath positioned below the workpiece to collect fluid falling from the workpiece. This segmentation allows each component to perform its specific collection function efficiently, preventing fluid wastage without requiring a completely complex integrated system.
Solution Approach 2:
The collection system transitions from a single horizontal plane (spill bath behind the dielectric bath) to a three-dimensional arrangement by adding a vertical dimension (drip bath below the workpiece). This dimensional change enables efficient collection of fluid falling vertically from the workpiece while maintaining the existing spill bath configuration for horizontal overflow.
2Loss of substance
If the drip bath is positioned directly below the workpiece to collect falling fluid, then fluid collection efficiency improves, but the machine design requires additional space and structural support
Solution Approach 1:
The drip bath is merged with the existing return system architecture, utilizing the same pump and fluid return infrastructure already present in the machine. This integration allows the drip bath to be added without requiring completely separate support systems, minimizing the additional volume and structural requirements.
Solution Approach 2:
The drip bath is positioned to utilize gravity for fluid collection, with the workpiece itself serving as the fluid delivery mechanism. Fluid falling from the workpiece is naturally directed into the drip bath below, eliminating the need for additional active collection mechanisms or complex positioning systems.
3Object-affected harmful factors
If a funnel or sloping surface is added to direct fluid into the drip bath, then fluid collection is improved and splashing is reduced, but manufacturing complexity increases
Solution Approach 1:
Instead of trying to prevent fluid from falling with complex barriers or containment structures, the solution inverts the approach by positioning the drip bath to actively receive and channel the falling fluid. The funnel or sloping surface is designed to work with gravity's natural direction, simplifying the manufacturing process while effectively reducing splashing.
Solution Approach 2:
The potentially harmful effect of fluid falling from the workpiece is converted into a beneficial collection opportunity. By positioning the drip bath to receive this falling fluid and using simple funnels or sloping surfaces to direct it, the system transforms what was previously wasteful splashing into efficient fluid recovery with minimal manufacturing complexity.
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 efficiently collects and recycles dielectric fluid, reducing wastage and splashing, and allows for a more compact machine design by eliminating the need for a saddle, thereby lowering costs and improving operational efficiency.
Implementation Method 1
A bath of dielectric fluid is provided so that said fluid is present in the gap
Implementation Method 2
By applying electrical pulses to the electrodes in a controlled manner, electricity flows between the electrodes and the roll surface creating a spark which creates the textured or matt finish
Implementation Method 3
dielectric fluid that falls directly from the workpiece
Implementation Method 4
a pump that pumps the fluid back to the dielectric bath
Data Source
AI summary
An EDT apparatus 1 is disclosed, comprising a dielectric fluid return system for use with an EDT machine of the type in which the workpiece is not submersed in dielectric fluid. The return system comprises a first collector 19 for catching spills from a dielectric bath 9 associated with a set of electrodes 10 which apply electrical pulses to the workpiece through the dielectric fluid in the bath. Also, a separate, second collector 21 is positioned substantially beneath the workpiece and arranged both to receive fluid from the first collector 19 and to catch fluid that drips from the workpiece itself, the second collector being connected to a pump 13 which returns the fluid from the second collector to the dielectric bath.