Wire Breakage Position Estimation from Take-Up Motor Torque
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Solution Overview
Problem
Existing wire electric discharge machines face challenges in accurately estimating the breakage position of a wire electrode without a tip detection electrode, leading to increased setup steps and potential tangling of the wire electrode during reverse winding.
Innovation Solution
A wire-breakage position estimation device and method that utilize a torque acquisition unit, determination unit, and rotation angle acquisition unit based on the winding motor's detection signal to estimate the breakage position without a tip detection electrode, allowing for reliable estimation of the wire electrode's breakage position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a tip detection electrode is installed on the wire electrode transfer path to detect breakage position, then the breakage position can be calculated, but the number of setup steps increases and the device complexity increases
Solution Approach 1:
The invention extracts the breakage position detection function from the mechanical/electrical detection system (tip detection electrode) and relocates it to the motor control system by monitoring torque variations in the winding motor. This eliminates the need for separate detection hardware while maintaining detection capability.
Solution Approach 2:
The winding motor serves dual functions: it performs the winding operation and simultaneously provides breakage position detection through its torque sensor. The system uses its own operational parameters (torque, rotation angle) for self-diagnosis, eliminating the need for external detection devices.
2Measurement precision
If the wire electrode is wound back in the opposite direction to reach the tip detection electrode for detecting breakage position, then the breakage position can be calculated, but the wire electrode may become tangled
Solution Approach 1:
Instead of moving the wire electrode backwards to reach the detection point (which causes tangling), the invention inverts the approach by placing the detection function at the winding motor where the wire naturally passes during normal forward winding operation. This eliminates the need for reverse movement entirely.
3Measurement precision
If the tip detection electrode is installed upstream of the breakage position to detect the tip, then the breakage position can be calculated from tip position and winding amount, but the method fails when breakage occurs upstream of the detection electrode
Solution Approach 1:
The torque-based detection system at the winding motor provides universal detection capability for all breakage positions along the wire path. Since the torque sensor monitors the force required to wind the wire, it can detect breakages anywhere from the wire source to the workpiece, making the system reliable under all breakage conditions.
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 and reliable estimation of the wire electrode's breakage position without the need for a tip detection electrode, reducing setup complexity and preventing wire tangling during reverse winding.
Implementation Method 1
a torque acquisition unit that acquires the torque of the winding motor based on the detection signal
Implementation Method 2
a rotation angle acquisition unit that acquires the rotation angle of the winding motor based on the detection signal
Data Source
AI summary
A wire-breakage position estimation device comprising: a torque acquisition unit which acquires a torque of a take-up motor; a determination unit which determines whether or not a rear end of a wire electrode has passed a take-up roller; a rotation angle acquisition unit which acquires a rotation angle of the take-up motor; and a wire-breakage position estimation unit which estimates a wire-breakage position in the wire electrode on the basis of the rotation angle acquired from when wire-breakage has occurred in the wire electrode to when the rear end has been determined to have passed the take-up roller.