Numerical Controller Workpiece Error Correction Wire EDM
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Solution Overview
Problem
Existing workpiece placement error correction techniques in wire electric discharge machining are ineffective for rough surfaces and do not accurately account for the positional relationship between wire guides and the machining area, leading to inaccuracies in correction.
Innovation Solution
A numerical controller that calculates workpiece placement error correction by using machining start holes, controlling the wire electrode's orientation, and adjusting the upper and lower wire guides based on the hole's diameter and center location, without requiring a dedicated measuring instrument like a touch sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch sensor is used to measure three representative points on the workpiece surface to calculate inclination, then the workpiece placement error correction can be performed, but the measurement becomes inaccurate when the workpiece surface is rough or undulated
Solution Approach 1:
The invention extracts the measurement process from the workpiece surface itself and relocates it to the machining start hole, which is a precise geometric feature created by the wire electrode. Instead of measuring the rough workpiece surface directly with a touch sensor, the system measures the inclination through the precisely formed hole, eliminating the interference of surface roughness and undulation.
Solution Approach 2:
The machining start hole serves as an intermediary medium between the workpiece and the measurement system. The hole, being a precise geometric feature, mediates the transfer of workpiece inclination information to the measurement system, allowing accurate inclination detection without direct contact with the rough workpiece surface.
2Manufacturing precision
If conventional wire perpendicular setting techniques are used to correct workpiece placement error, then the wire electrode inclination can be corrected, but the positional relationship between the wire guides and the machining area is not accurately accounted for
Solution Approach 1:
The invention implements a feedback mechanism where the actual position and orientation of the machining start hole are measured, and this information is used to calculate and apply corrective adjustments to the wire guide positions. The system continuously refines the positional relationship between the wire guides and the machining area based on measured deviations, ensuring high precision in both wire perpendicularity and workpiece placement correction.
3Measurement precision
If a dedicated measuring instrument such as a touch sensor probe is used for workpiece placement error correction, then the inclination can be measured, but the process time increases due to instrument setup and removal
Solution Approach 1:
The workpiece itself, through its machining start hole, serves the dual function of both the object to be machined and the measurement reference. The machining start hole, created as part of the normal machining process, automatically provides the geometric reference needed for inclination measurement, eliminating the need for separate dedicated measuring instruments and their associated setup and removal time.
Solution Approach 2:
The machining start hole performs multiple functions: it serves as the entry point for the wire electrode for machining operations and simultaneously serves as the reference feature for measuring workpiece inclination. This multi-functionality eliminates the need for separate measurement features or instruments, streamlining the process and reducing time loss.
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
Enables accurate workpiece placement error correction regardless of surface roughness and undulation, improving precision and eliminating the need for dedicated measuring instruments, thus saving time.
Implementation Method 1
a wire electrode; an inclination degree calculation unit configured to calculate an inclination of the workpiece with respect to the XY axis on the basis of a position of the UV axis in response to the wire electrode being made to be perpendicular to the workpiece by the perpendicular setting control unit
Data Source
AI summary
A numerical controller controlling a wire electric discharge machining device of the present invention is configured to perform perpendicular setting of the wire electrode with respect to the workpiece while the wire electrode is inserted into and passed through a machining hole of a workpiece and calculate the inclination of the workpiece; drive an XY axis and detect short-circuit; obtain the diameter of the machining start hole; subsequently drive the upper wire guide and the lower wire guide respectively and detect the short-circuit and calculate the location of the center of the upper portion of the machining start hole and the location of the center of the lower portion of the machining start hole; and, based on these calculated values, calculate the correction amount for the workpiece on the upper wire guide surface of the upper wire guide and the correction amount for the workpiece on the lower wire guide surface of the lower wire guide.