Wire Bobbin Remaining Amount Estimation Using Rotation Ratios

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Solution Overview

Problem

Conventional methods for estimating the remaining amount of a wire electrode in a wire electric discharge machine require operators to measure the degree of denseness and winding diameter, imposing a significant burden and complexity.

Innovation Solution

A remaining amount estimation device and method that utilize rotational position detection sensors to calculate the wire remaining amount based on ratios of rotation between the wire bobbin and feed roller at specific times, eliminating the need for direct measurement of denseness and diameter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the conventional technique using degree of denseness and winding diameter measurement is employed, then the wire remaining amount can be calculated, but the operator burden increases due to requiring measurements of both parameters

Engineering Contradiction:

Improvewire remaining amount calculation accuracyVSAvoidoperator burden

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The invention extracts only the essential measurement (winding diameter) from the conventional two-parameter measurement system (denseness + winding diameter). By eliminating the denseness measurement requirement and using only winding diameter combined with rotational position data, the system maintains calculation accuracy while significantly reducing operator burden.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention introduces rotational position detection sensors as an intermediary element that indirectly provides information about wire consumption. Instead of directly measuring denseness and winding diameter, the system uses rotational positions of the wire bobbin and feed roller to calculate wire remaining amount, simplifying the measurement process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If multiple measurement parameters (degree of denseness and winding diameter) are required, then calculation accuracy is maintained, but the measurement process becomes more complex

Engineering Contradiction:

Improvewire remaining amount calculation accuracyVSAvoidmeasurement process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces manual measurement processes with automated rotational position detection sensors. The sensors automatically track the rotational positions of the wire bobbin and feed roller, eliminating the need for manual measurement operations and reducing measurement process complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20240316666A1Remaining amount estimation device and remaining amount estimation method

Publication Date: 2024.09.26 FANUC LTD

AI summary

A remaining amount estimation device estimates the remaining amount of wire on a wire bobbin on which a wire electrode has been wound and comprises: an acquisition unit that acquires a first rotational position for the wire bobbin and a second rotational position for a delivery roller that delivers the wire electrode; and a first estimation computation unit that estimates the remaining amount of wire using the ratio of the rotation amount of the wire bobbin and the delivery roller at each of a start time and an end time of a prescribed time period and the total rotation amount that the delivery roller has rotated during the prescribed time period.