Wire Bobbin Empty-State Detection for EDM Wire Waste Reduction
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Solution Overview
Problem
Existing wire electric discharge machining devices often waste wire electrodes by stopping the delivery before the wire bobbin reaches an empty state, leading to unnecessary wire wastage, as they prioritize safety over efficient resource management.
Innovation Solution
A wire electric discharge machining device equipped with a rotation speed detection system that determines the empty state of the wire bobbin based on a rapid change in rotation speed, triggering the drive control to stop the wire delivery, thereby preventing the wire electrode from entering the machining clearance and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the delivery of the wire electrode is stopped before the wire bobbin reaches an empty state, then the work-piece is protected from damage, but the wire electrode is wasted
Solution Approach 1:
The patent replaces mechanical detection methods (such as sensors detecting wire presence) with a calculation-based approach. The control unit calculates the remaining wire length by integrating the rotation speed of the wire bobbin over time, and determines emptiness when the calculated length reaches zero. This substitution allows for more precise control and eliminates the need to stop delivery early, thereby preventing wire waste while maintaining work-piece quality.
Solution Approach 2:
The system continuously monitors the rotation speed of the wire bobbin and feeds this information back to the control unit. The control unit integrates this feedback data to calculate the remaining wire length in real-time, and uses this information to determine the optimal moment to stop delivery precisely when the wire bobbin is empty, rather than stopping early as a safety precaution.
2Loss of substance
If the delivery of the wire electrode continues after the wire bobbin is empty, then wire electrode waste is reduced, but the work-piece machining surface is damaged
Solution Approach 1:
The system performs preliminary calculation of the remaining wire length based on accumulated rotation data before the wire bobbin actually becomes empty. By continuously integrating rotation speed data, the system predicts when the wire will be exhausted and stops the delivery mechanism at this predicted point, preventing both wire waste and machining surface damage by avoiding the empty state entirely.
3Loss of substance
If a rotation speed detection system is implemented to detect empty state, then wire electrode waste is minimized, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical detection systems (such as sensors, switches, or mechanical indicators) with a computational approach. The control unit uses software-based integration of the wire bobbin's rotation speed signal to calculate remaining wire length and determine emptiness. This substitution reduces mechanical complexity while achieving precise empty state detection, thereby minimizing wire electrode waste without significantly increasing overall device complexity.
Data Source
AI summary
The wire electric discharge machining device includes a wire bobbin configured to wind and hold a wire electrode, a wire delivery roller configured to draw the wire electrode from the wire bobbin and deliver the wire electrode continuously toward a work-piece, a brake motor configured to apply a load to the wire bobbin in a direction against the drawing of the wire electrode, rotation speed detector configured to detect a rotation speed of the wire bobbin, an emptiness determination device configured to determine that the wire bobbin reaches an empty state based on a rapid change in the rotation speed of the wire bobbin detected by the rotation speed detector, and a drive control part configured to stop the drive of the wire delivery roller when the emptiness determination device determines that the wire bobbin reaches the empty state.