Wire EDM Connection Hole Position Correction
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Solution Overview
Problem
Conventional wire electric discharge machines face challenges in efficiently and automatically connecting wire electrodes due to irregularities in the position or roundness of connection holes, leading to reduced productivity and increased labor, as existing methods are ineffective in dealing with deviations beyond the search range and require extensive manual intervention.
Innovation Solution
A wire electric discharge machine with a control unit that automatically interrupts the program operation if the connection hole is deviated, stores the correct connection position, compares and adjusts the wire electrode's position, and restarts the program once the electrode is returned to the correct position, allowing for automatic continuation of machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automatic wire electrode connection is attempted using conventional methods (repetition, water/air assistance, XY-table search), then connection success rate may be improved in some cases, but the system cannot properly deal with abnormality such as irregularity in the position or roundness of the connection hole, and requires extensive manual intervention when automatic connection fails
Solution Approach 1:
The control unit stores the correct connection position information before attempting wire electrode connection. When connection fails, the system uses the pre-stored position information to automatically guide the wire electrode to the correct position, eliminating the need for manual position searching and intervention.
Solution Approach 2:
The control unit detects connection failure and automatically compares the actual wire electrode position with the stored correct connection position. Based on this feedback, the system automatically adjusts the wire electrode position to match the correct connection position, enabling automatic correction without manual intervention.
2Ease of operation
If manual intervention is performed to correct connection hole position deviation, then wire electrode can be connected, but the process requires extensive manual operations including moving XY-table, aligning wire electrode, and returning to original position, significantly increasing operation time
Solution Approach 1:
When wire electrode connection fails, the control unit automatically performs all correction operations including moving the wire electrode to the correct position, executing the connection, and returning to the original machining position. The system serves itself without requiring manual intervention, significantly reducing operation time.
Solution Approach 2:
The control unit stores the original machining position information before connection attempts. After automatic correction and successful connection, the system uses the pre-stored position information to automatically return to the original machining position, eliminating manual position recall and reducing time loss.
3Reliability
If XY-table search operation pattern is used to locate connection hole, then connection may be achieved within search range, but the method is time-consuming and requires expensive search equipment, and fails when hole position is outside search range
Solution Approach 1:
Instead of using complex physical search equipment to locate the connection hole, the control unit uses a digital copy (stored position information) of the correct connection position. This virtual positioning system eliminates the need for expensive search equipment and expands the effective search range to the entire workpiece area.
Solution Approach 2:
The patent replaces the mechanical XY-table search operation with a control-based automatic positioning system. The control unit directly moves the wire electrode to the stored connection position using control signals, eliminating the need for manual mechanical search operations and reducing equipment complexity.
4Productivity
If conventional automatic connection methods are used, then some connection failures can be handled by repetition or assistance, but they cannot properly deal with position or roundness irregularity of connection holes, leading to reduced productivity
Solution Approach 1:
The control unit detects connection failure and automatically compares actual position with stored correct position. This feedback mechanism enables the system to handle any position or roundness irregularity by automatically calculating and executing the correction needed, significantly improving both reliability and productivity.
Solution Approach 2:
The system changes the control parameters dynamically based on the detected position deviation. When connection fails, the control unit adjusts the wire electrode position parameters to match the stored correct connection position, enabling the system to adapt to various irregularities in connection holes and maintain high productivity.
Data Source
AI summary
A wire electric discharge machine configured to interrupt a program operation if a connection hole for connecting a wire electrode is located in a position deviated from a wire electrode connection position on a machining path so that connection by a wire electrode connection unit is not completed and store the wire electrode connection position, and to restart the program operation after performing machining such that the wire electrode is returned to the wire electrode connection position by automatic control and machining to widen a machined groove portion in the wire electrode connection position, when subjected to a re-machining operation after manual connection of the wire electrode in the position of the connection hole.