Wire EDM Control for Accurate Electrode Consumption Tracking
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Solution Overview
Problem
Existing wire electric discharge machines (WEDMs) face challenges in accurately measuring the total consumption of the wire electrode during machining interruptions and resumptions.
Innovation Solution
A control device and method for WEDM that includes a machining control unit, an acquisition unit, a measurement unit, and a consumption amount calculation unit. This setup allows for the measurement of wire electrode consumption before and after machining interruptions, enabling the calculation of a total consumption amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If machining is interrupted to perform second machining on a different workpiece, then productivity is improved through flexible scheduling, but measurement precision of total wire electrode consumption deteriorates because the consumption amount cannot be accurately obtained
Solution Approach 1:
The control device stores the wire electrode consumption amount from the first machining before interruption occurs. This preliminary storage of data enables accurate calculation of total consumption even after the machining is interrupted and resumed later, resolving the measurement precision issue while maintaining productivity flexibility
Solution Approach 2:
The control device calculates and provides feedback on the total wire electrode consumption by combining the stored consumption amount from before interruption with the consumption amount after resumption. This feedback mechanism ensures accurate measurement is maintained despite the interruption and resumption of machining operations
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
Enables accurate determination of the total wire electrode consumption during machining interruptions and resumptions, improving operational efficiency and cost calculation in WEDM processes.
Implementation Method 1
an acquisition unit configured to acquire a detection signal from a sensor configured to detect a rotational position of a roller configured to feed out a wire electrode
Data Source
AI summary
A control device for executing a control method for controlling a wire electrical discharge machine includes a machining control unit that interrupts first machining, and resumes the first machining after completion of second machining; an acquisition unit that acquires a detection signal from a sensor; a measuring unit that measures, on the basis of the detection signal, a first consumption amount of a wire electrode from the start to the interruption of the first machining, and a second consumption amount from the resuming to the end of the first machining; and a consumption amount calculation unit that calculates a first total consumption amount of the wire electrode consumed in the first machining.