Swing Pulley Wire Feed Layout to Prevent EDM Wire Bending
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Solution Overview
Problem
Conventional wire electrical discharge machining devices face issues with the wire electrode being permanently bent or twisted when released from the wire bobbin, especially at large entry angles, which affects the precision of the machining process.
Innovation Solution
A wire electrical discharge machining device is designed with a first pulley that is swingably arranged in the horizontal direction, with its fulcrum disposed within the width direction of the wire bobbin, allowing the wire electrode to be guided without permanent bending or twisting by adjusting its path to maintain a stable tension and prevent undesired movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wire electrode is released from the wire bobbin at a large entry angle, then the wire electrode can be fed out from the bobbin, but the wire electrode becomes permanently bent or twisted and lands on another location over the wound wire electrode
Solution Approach 1:
A guide roller is introduced as an intermediary component between the wire bobbin and the wire guide. This guide roller receives the wire electrode from the bobbin and guides it to the wire guide, acting as a mediator that prevents direct sharp bending at the wire guide while maintaining proper wire tension and alignment throughout the feeding path.
Solution Approach 2:
The system allows dynamic adjustment of the wire electrode path through the guide roller's position and orientation. The guide roller can be positioned to optimize the entry angle dynamically, enabling smooth wire release from the bobbin while preventing permanent bending, thus adapting to different operating conditions without compromising machining precision.
2Speed
If the wire electrode is sharply bent by the wire guide when released from the end of the wire bobbin, then the wire electrode can be transmitted to the pulley, but the wire electrode risks permanent bending
Solution Approach 1:
The guide roller serves as a intermediary that buffers the sharp bending action. Instead of the wire electrode being sharply bent directly by the wire guide, the guide roller first receives and gently redirects the wire, then transmits it to the wire guide, thereby maintaining wire integrity while ensuring efficient transmission to the pulley.
Solution Approach 2:
The guide roller provides beforehand cushioning by creating a gradual transition path for the wire electrode before it reaches the wire guide. This pre-cushioning effect prevents sudden sharp bends that could cause permanent deformation, ensuring the wire maintains its structural integrity during the transmission process.
3Manufacturing precision
If the wire electrode directly enters the pulley without a wire guide, then the entry angle can be reduced, but the wire electrode may be twisted by the force acting on it in the V-groove of the pulley
Solution Approach 1:
The guide roller acts as an intermediary between the wire bobbin and the pulley, controlling the wire's path and reducing the entry angle to the pulley. This intermediary role ensures the wire enters the pulley's V-groove at a more favorable angle, minimizing twisting forces while maintaining proper alignment for precise machining operations.
Data Source
AI summary
In a wire electrical discharge machining device, a wire electrode released from a wire bobbin can be supplied toward a wire electrical discharge machining portion without generating permanently bending or twisting. A first pulley, which receives a wire electrode fed out from a wire bobbin and delivers the wire electrode to the downstream side, is disposed to wind the wire electrode WE to a first delivery position of an outer peripheral portion opposite to a first reception position across a central portion in a radial direction and deliver the wire electrode WE downward. The first pulley is swingable in the horizontal direction with one end in the radial direction as a fulcrum. The swing fulcrum is disposed, in the width direction of the wire bobbin, within a range from one end to the other end in the width direction of the wire bobbin.