Wire EDM Positioning Accuracy Compensation Using Contact Detection Jigs
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Solution Overview
Problem
Wire electric discharge machines face challenges in maintaining positioning accuracy due to installation state variations, machining liquid weight, and workpiece weight, which are difficult to measure and compensate for using expensive high-precision devices like laser interferometers.
Innovation Solution
The implementation of a wire electric discharge machine with contact detection jigs and a compensation unit that calculates and adjusts for positioning errors by measuring distances between jigs under different states, allowing for accurate machining liquid levels and floor strength compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive high-precision measurement devices such as laser interferometer and pitch master are used to measure positioning accuracy, then positioning accuracy can be measured and compensated, but the cost increases and the installation and operation become difficult
Solution Approach 1:
The patent replaces expensive high-precision measurement devices with simple, inexpensive contact detection jigs that can be easily manufactured and disposed of. These jigs make multiple contact points with the workpiece to detect positioning deviations, providing an affordable alternative to laser interferometers and pitch masters while maintaining sufficient measurement capability for compensation purposes
Solution Approach 2:
The patent creates a simplified copy of the measurement function by using contact detection jigs that replicate the essential measurement capability without requiring complex optical systems. The jigs establish contact at multiple points to define a reference coordinate system, copying the positioning measurement function in a mechanically simple way that avoids the complexity of laser-based systems
2Ease of operation
If positioning accuracy is measured in assembly plant without machining liquid, then measurement can be performed, but the actual positioning accuracy during machining with machining liquid and workpiece may not meet reference value
Solution Approach 1:
The patent performs preliminary positioning accuracy measurement and compensation by placing contact detection jigs on the table before actual machining begins. The system measures positioning deviations under the actual machining conditions (with machining liquid and workpiece weight present) and pre-calculates compensation values that are stored and applied during subsequent machining operations, ensuring accuracy is maintained throughout the machining process
Solution Approach 2:
The patent implements a feedback mechanism where contact detection jigs continuously monitor positioning accuracy during machining operations. The detected deviations are fed back to the control system, which automatically adjusts the positioning instructions to compensate for errors caused by machining liquid weight and workpiece weight, maintaining positioning accuracy dynamically throughout the machining process
3Adaptability or versatility
If machine is installed in user's plant with different floor strength and leveling state, then machine can be used, but positioning accuracy changes due to different deflection
Solution Approach 1:
The patent adapts to different installation environments by dynamically changing the positioning parameters through compensation. The contact detection jigs measure actual positioning deviations under the specific user's plant conditions (different floor strength, leveling state, and gravitational effects), and the control system adjusts positioning instructions based on these measured parameters, allowing the machine to maintain accuracy across varying installation conditions without requiring physical modifications to the machine structure
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 solution improves positioning accuracy by enabling effective compensation for changes in installation state, machining liquid weight, and workpiece weight, enhancing machining precision without the need for expensive measurement devices.
Implementation Method 1
a contact detection unit for detecting contact between the wire electrode and the first and second contact detection jigs
Data Source
AI summary
Two contact detection jigs are spaced apart and attached on a table on which a workpiece to be machined by a wire electric discharge machine is placed, and first, under a state serving as a reference, a distance between these two contact detection jigs (a reference distance) is measured by bringing the wire electrode into contact with these contact detection jigs. Subsequently, in a state of actual use, the wire electrode is brought into contact with these contact detection jigs in the same manner, so that a distance between these two contact detection jigs (an actual distance) is measured. Then, based on the difference between the reference distance and the actual distance, the amount of compensation is obtained to compensate an instruction for moving the wire electrode with respect to the table.