Conductive Spherical Measuring Jig for Inclined Wire EDM Tables
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Solution Overview
Problem
Current methods for measuring reference points on inclined rotating tables in wire electric discharge machines face challenges due to the difficulty in accurately using the contact sensing function of wire electrodes, particularly in machining bevel gears with cone angles beyond 45°, leading to measurement errors and increased time for measurement due to the need for sharp edges and precise distance calculations between wire electrode and probe centers.
Innovation Solution
A measuring jig with a conductive spherical surface is used, allowing the wire electrode to contact the spherical surface from opposing directions to measure multiple points, calculating the center point position and reference coordinates on the table center by combining height, angle, and position measurements, leveraging the contact sensing function of wire electric discharge machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a test bar with a sharp edge is used for measurement, then the reference point can be measured using a wire electrode, but measurement errors occur due to difficulty in machining and stabilizing the sharp edge
Solution Approach 1:
The patent replaces the sharp edge of a traditional test bar with a spherical surface. The spherical surface is machined with high precision and can be easily measured by the wire electrode through contact sensing. The wire electrode contacts the spherical surface at its apex, eliminating the need for difficult sharp edge machining while maintaining measurement accuracy. The spherical geometry provides a stable, repeatable contact point that is easy to manufacture and measure.
2Measurement precision
If the relative distance between wire electrode center and probe center is accurately obtained, then measurement accuracy improves, but the measurement time increases due to needing to obtain the distance with each probe replacement
Solution Approach 1:
The patent makes the wire electrode itself the measuring tool by utilizing its contact sensing function. The wire electrode directly measures the spherical surface on the measuring jig, eliminating the need for separate probe measurements. The system uses the wire electrode's own position and contact points to calculate the reference coordinates, making the measurement process self-contained and eliminating time-consuming probe replacement procedures.
3Adaptability or versatility
If an inclined rotating table is used to machine bevel gears with cone angles beyond 45°, then the machining capability is improved, but the reference point measurement becomes more difficult due to the inclined position
Solution Approach 1:
The patent introduces a spherical surface measurement approach that works effectively in three-dimensional space regardless of the table's inclination angle. By measuring the spherical surface from multiple angles and positions, the system can calculate the reference point coordinates even when the rotating table is inclined at various angles. This dimensional approach to measurement overcomes the limitations of traditional edge-based methods on inclined surfaces.
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 provides accurate and efficient measurement of reference points on inclined rotating tables, reducing measurement errors and time by utilizing the contact sensing function effectively, enabling machining of bevel gears with higher cone angles.
Implementation Method 1
a wire electric discharge machine generally has a contact sensing function of a wire electrode
Data Source
AI summary
A reference point on a table center of an inclined rotating table in a wire electric discharge machine is obtained using a measuring jig. A biaxial rotation unit is placed on a table of the wire electric discharge machine. The measuring jig has a shape most suitable for reference point measurement using a contact sensing function of a wire electrode which a wire electric discharge machine generally has and includes a fixed section for being fixed to a work fixing section of the biaxial rotation unit, an arm section which is provided to stand on the fixed section, and a section to be measured which is provided at a distal end of the arm section and has a conductive spherical surface.