Wire EDM Workpiece Lifting for Core Removal Accuracy
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Solution Overview
Problem
In wire electrical discharge machining, small cores can fall into lower nozzles, making it difficult to remove them without detaching the workpiece from the work table, which can lead to machining accuracy issues.
Innovation Solution
A wire electrical discharge machine with a lifting mechanism that moves the workpiece in the Z-axis direction to create space between the workpiece and the lower nozzle, allowing for core removal without detaching the workpiece, using a drop detection sensor and articulated robot for core collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the workpiece is detached from the work table to remove the core from the lower nozzle, then the core can be removed, but the machining accuracy deteriorates due to positioning errors
Solution Approach 1:
The patent introduces a lifting mechanism that moves the workpiece in the vertical dimension (Z-axis), perpendicular to the work table plane. This dimensional change allows the workpiece to be raised above the lower nozzle for core removal while remaining attached to the work table, thus achieving core access without compromising horizontal positioning accuracy.
2Manufacturing precision
If the workpiece remains attached to the work table, then machining accuracy is maintained, but the core cannot be removed from the lower nozzle
Solution Approach 1:
The lifting mechanism transforms the static workpiece positioning into a dynamic system where the workpiece can be vertically displaced. This dynamic capability allows the workpiece to move upward when core removal is needed, creating temporary clearance with the lower nozzle while maintaining attachment to the work table.
3Ease of operation
If a lifting mechanism is added to move the workpiece vertically, then core removal becomes possible without detaching the workpiece, but the device complexity increases
Solution Approach 1:
The lifting mechanism serves multiple functions: it enables core removal by creating vertical clearance, maintains workpiece positioning accuracy by keeping the workpiece attached to the work table, and works cooperatively with the articulated robot for automated core collection. This multi-functionality justifies the added complexity.
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 the removal of cores without compromising machining accuracy by maintaining the workpiece's position on the table, facilitating automatic core collection and preventing interference with the upper nozzle.
Implementation Method 1
applying voltage across an electrode gap between a wire electrode stretched between an upper nozzle and a lower nozzle and the workpiece to generate electrical discharges
Implementation Method 2
a lifting mechanism configured to move the workpiece in a travelling direction of the wire electrode
Data Source
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AI summary
A wire electrical discharge machine (12) for performing electrical discharge machining on a workpiece (W) by applying voltage across an electrode gap between a wire electrode (18) stretched between an upper nozzle (36) and a lower nozzle (38) and the workpiece (W) to generate electrical discharges, includes a lifting mechanism (64) configured to move the workpiece (W) in the travelling direction of the wire electrode (18).