Wire EDM Axis Feeding Control for Liquid Spill Prevention
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Solution Overview
Problem
In wire electrical discharge machines, the process liquid in the tank often spills during axis feeding operations, especially when the liquid level is high, posing safety risks and operational inefficiencies, as existing technologies do not account for adjusting axis feeding speeds based on liquid levels.
Innovation Solution
A wire electrical discharge machine equipped with a liquid level information acquiring unit and an axis feeding property changing unit that adjusts axis feeding properties, such as speed, acceleration, and jerk, based on the process liquid level information to prevent spilling, including reducing these parameters when the liquid level is high.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If axis feeding operation is carried out at high speed to improve productivity, then productivity increases, but process liquid spills from the process tank
Solution Approach 1:
The patent applies dynamics by making the axis feeding speed variable rather than fixed. The control unit dynamically adjusts the axis feeding speed based on the process liquid level detected by the level detection sensor. When the liquid level is high, the feeding speed is reduced to prevent spilling; when the liquid level is low, the feeding speed can be increased to improve productivity. This dynamic adjustment resolves the contradiction between maintaining high productivity and preventing process liquid spilling.
2Loss of time
If axis feeding speed is increased to reduce preparation time, then preparation time decreases, but process liquid undulation and spilling increases
Solution Approach 1:
The patent applies parameter changes by modifying the axis feeding speed parameter based on the process liquid level. The control unit receives level information from the level detection sensor and adjusts the feeding speed parameter accordingly. This allows the system to optimize preparation time by using higher speeds when safe, while preventing spilling by reducing speed when the liquid level is high, thus resolving the contradiction between reducing preparation time and preventing harmful spilling.
3Device complexity
If fixed axis feeding speed is used to simplify control, then device complexity decreases, but ability to prevent spilling deteriorates
Solution Approach 1:
The patent applies feedback by implementing a control loop where the level detection sensor continuously monitors the process liquid level and feeds this information to the control unit. The control unit then adjusts the axis feeding speed based on this feedback. This feedback mechanism enables the system to automatically prevent spilling without requiring complex manual intervention, resolving the contradiction between maintaining simple control and achieving reliable spilling prevention.
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
The upper limit value for the axis feeding speed is set to the maximum speed that can secure the safety in a wire electrical discharge machine. In the case where the level of the process liquid is higher than a predetermined height, however, the upper limit value is made smaller. In order to prevent the process liquid from spilling to the outside of the process tank, the acceleration or the jerk may be changed instead of the axis feeding speed. In the case where the process liquid level is high, it is difficult for the process liquid to spill when the speed is adjusted slowly. In addition, the time constant may be increased or the instruction for speed may be changed from the linear type to the S shape type.