Wire EDM Control Device Core Fixing Distance Adjustment
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Solution Overview
Problem
Existing wire electrical discharge machining techniques fail to ensure a strong enough fixing force for cores when machining shapes are enlarged or reduced, leading to a risk of core instability due to inadequate consideration of workpiece thickness in fixing portion conversion.
Innovation Solution
A control device that adjusts the machining shape and fixing distance in a machining program based on both the enlargement/reduction ratio and the plate thickness ratio of the workpiece, ensuring the fixing distance is sufficient to maintain core stability during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the deposition regions are converted according to the enlargement/reduction ratio of the machining shape, then the machining shape can be scaled properly, but the fixing force of the core becomes insufficient when workpiece thickness is not considered
Solution Approach 1:
The patent applies local quality by differentiating the conversion approach for different parts of the program: the machining shape is converted using the enlargement/reduction ratio, while the fixing distance is converted using a separate calculation that incorporates workpiece thickness. This allows each parameter to be optimized independently according to its specific requirements.
Solution Approach 2:
The patent changes the parameters used for conversion by introducing the workpiece thickness as an additional factor. Instead of using only the enlargement/reduction ratio for all conversions, the fixing distance conversion uses a composite ratio that includes both the shape scaling ratio and the thickness ratio, thereby adapting the fixing strength to the actual workpiece dimensions.
2Device complexity
If the fixing distance is converted using only the enlargement/reduction ratio, then the program conversion is simple, but the core stability cannot be ensured for different workpiece thicknesses
Solution Approach 1:
The patent performs preliminary action by calculating and storing the workpiece thickness before the program conversion process. This pre-calculated thickness information is then used during the fixing distance conversion to ensure core stability, rather than attempting to adjust for thickness during the conversion process itself.
Solution Approach 2:
The patent introduces an intermediary calculation step that combines the enlargement/reduction ratio with the workpiece thickness ratio to produce a corrected conversion ratio. This intermediary value serves as a mediator between the simple shape scaling requirement and the complex core stability requirement.
Data Source
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AI summary
A control device includes: a control unit (58) configured to control a main processing machine (14) by replacing a machining shape (S1) on a machining surface (P) of a workpiece (W) specified in a program with a shape (S2) corresponding to an enlargement/reduction ratio (Ms) and replacing a fixing distance (D1) for a core (C) specified in the program with a distance (D2) corresponding to the enlargement/reduction ratio (Ms) for the machining shape of the workpiece (W) and a plate thickness ratio (Mh) between the workpieces.