Wire EDM Component Consumption Prediction for Planned Maintenance
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Solution Overview
Problem
Existing wire electrical discharge machines lack the ability to predict the extent of component wear and tear prior to machining, making it difficult to anticipate and manage component consumption during future machining processes.
Innovation Solution
A prediction device connected to wire electrical discharge machines that predicts the rate of component consumption based on machining conditions, using a prediction unit and display unit to provide operators with anticipated consumption rates and amounts, allowing for proactive maintenance and component replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If component consumption is monitored after machining, then wear and tear can be grasped, but the extent of future component consumption cannot be predicted
Solution Approach 1:
The patent calculates the predicted rate of consumption before machining operations begin, using the machining condition data stored in the storage unit. This preliminary calculation allows operators to predict component consumption in advance, enabling proactive maintenance planning and avoiding unexpected machine interruptions.
2Productivity
If machining is performed without consumption prediction, then productivity is maintained, but machine interruption risk increases
Solution Approach 1:
The prediction calculation unit provides continuous feedback about component consumption rates based on machining conditions. This feedback mechanism allows operators to monitor component wear trends and schedule maintenance proactively, ensuring machine reliability without compromising productivity through unexpected interruptions.
3Duration of action of moving object
If component replacement is delayed, then operational time is maximized, but consumption rate increases
Solution Approach 1:
By calculating the predicted rate of consumption before machining, the system enables operators to plan component replacement at optimal intervals. This preliminary prediction allows maximizing component service life while preventing excessive wear, as operators can schedule replacements based on predicted consumption rates rather than reacting to actual wear after failure occurs.
Data Source
AI summary
Provided is a prediction device, to which one or more wire electrical discharge machines are connected, the one or more wire electrical discharge machines each performing machining on an object to be machined according to a predetermined machining condition while moving a wire electrode relatively with respect to the object to be machined along a machining path, the prediction device including a prediction unit that predicts, for a predetermined component constituting the wire electrical discharge machine, a predicted rate of consumption indicative of a rate of consumption based on the machining condition when the wire electrode is moved relatively by a unit distance, and a display unit that displays the predicted rate of consumption of the component.