Wire Electric Discharge Machine Adhesion Control
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Solution Overview
Problem
Conventional wire electric discharge machines face challenges in achieving reliable adhesion of wire electrode constituents to the workpiece core, leading to insufficient deposition during machining, as the gradient of the current rise is not adequately managed, resulting in core dropping issues.
Innovation Solution
A wire electric discharge machine is designed with a variable DC power supply and a control unit that lowers the output voltage and extends the on-time of the second switching element's signal, allowing for reliable adhesion of wire electrode constituents to the machining groove by modifying electrical conditions in the machining path, eliminating the need for wide pulses and third switching elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machining power supply with fixed voltage and short on-time is used, then normal machining efficiency is maintained, but wire electrode constituents cannot reliably adhere to the workpiece core, causing core dropping
Solution Approach 1:
The patent applies dynamics by making the power supply voltage and on-time variable rather than fixed. The control unit dynamically adjusts the output voltage of the variable DC power supply and extends the on-time of the second switching element signal based on the machining stage, transitioning from normal machining parameters to welding parameters to ensure reliable adhesion at critical moments while maintaining efficiency during normal operation.
Solution Approach 2:
The patent changes the electrical parameters (voltage and time) of the power supply system. Specifically, it lowers the output voltage of the variable DC power supply and extends the on-time of the second switching element signal during welding stages. This parameter modification creates favorable conditions for wire electrode constituents to adhere to the workpiece core, resolving the adhesion reliability issue without requiring complex additional components.
2Manufacturing precision
If the gradient of current rise is not managed, then simple power supply control is maintained, but insufficient deposition occurs leading to core dropping
Solution Approach 1:
The patent controls the gradient of current rise by modifying the voltage and time parameters of the power supply. By lowering the output voltage and extending the on-time, the system achieves a gentler current rise gradient that facilitates proper deposition of wire electrode constituents. This approach maintains relatively simple device structure while achieving precise deposition control through parameter optimization.
3Reliability
If wide pulses and third switching elements are used to improve adhesion, then reliable deposition is achieved, but device complexity and circuit structure are increased
Solution Approach 1:
The patent achieves reliable adhesion by changing the electrical parameters (lower voltage, extended on-time) rather than adding circuit components. This parameter-based solution avoids the need for wide pulses and third switching elements, maintaining a relatively simple circuit structure while achieving the desired deposition reliability. The variable DC power supply and control unit provide sufficient flexibility to create favorable welding conditions without increasing device complexity.
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 configuration ensures reliable adhesion and deposition of wire electrode constituents, preventing core dropping by adjusting voltage and current timing, thereby enhancing machining precision and efficiency.
Implementation Method 1
apply a voltage to a machining gap between the wire electrode and a workpiece to generate electric discharge
Implementation Method 2
deposit the constituents of the wire electrode between the workpiece and the portion to be cut off from the workpiece to bond the workpiece and the portion to be cut off
Data Source
AI summary
In a wire electric discharge machine, a control unit is configured to deposit constituents of a wire electrode between a workpiece and a portion to be cut off from the workpiece to bond the workpiece and the portion to be cut off by outputting a signal for making an output voltage of a variable DC power supply lower than during normal machining and the on-time of a second switching element longer than during the normal machining, at least in a part of a machining path.