Wire EDM Current Control for Faster Machining Without Wire Breakage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing wire electrical discharge machines face issues with increased machining speed leading to frequent breakage of the wire electrode due to high machining currents.
Innovation Solution
A wire electrical discharge machine with a discharge gap state determination unit, recording unit, machining current setting unit, and control unit that adjusts the machining current based on the discharge gap state, supplying normal current in a normal state, reduced current in a short-circuited state, and no current in an open state to prevent electrode breakage while enhancing machining speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machining current is increased to enhance machining speed, then the machining speed is improved, but the wire electrode frequently breaks
Solution Approach 1:
The patent implements dynamic adjustment of machining current based on real-time discharge gap state detection. The control unit varies the machining current magnitude according to the detected discharge gap conditions (normal, short-circuited, or open state), transitioning from static to dynamic current control. This resolves the contradiction by allowing high current when conditions permit (improving speed) while reducing current when risks arise (preventing breakage).
Solution Approach 2:
The patent employs a feedback mechanism where the discharge gap state determination unit continuously monitors the discharge gap state and feeds this information back to the machining current control unit. Based on this feedback, the system adjusts the machining current in real-time. When the discharge gap state indicates normal operation, higher current is supplied for faster machining; when abnormal states are detected, current is reduced or interrupted to prevent wire breakage, thus resolving the speed-breakage contradiction.
2Reliability
If the machining current is reduced to suppress wire electrode breakage, then the reliability is improved, but the machining speed decreases
Solution Approach 1:
The system dynamically adjusts machining current based on real-time discharge gap state rather than using a fixed low current setting. When the discharge gap state is normal, the system supplies high machining current to maintain fast machining speed. When abnormal states (short-circuited or open) are detected, the current is reduced or stopped to prevent breakage. This dynamic approach resolves the contradiction by allowing high speed when safe and low current only when necessary.
Solution Approach 2:
The patent changes the machining current parameter dynamically based on discharge gap state detection. Instead of maintaining a constantly low current to prevent breakage, the system varies the current magnitude according to detected conditions: high current for normal states (maintaining speed) and low or zero current for abnormal states (preventing breakage). This parameter change strategy resolves the contradiction between reliability and productivity.
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
The solution effectively increases machining speed while reducing the risk of wire electrode breakage by optimizing the machining current based on discharge gap states, ensuring efficient energy input and extended electrode lifespan.
Implementation Method 1
machining a workpiece by generating electric discharge at a discharge gap between the workpiece and a wire electrode
Implementation Method 2
main discharge circuit configured to supply machining current to the discharge gap
Data Source
AI summary
A wire electrical discharge machine for machining a workpiece by generating electric discharge at a discharge gap between the workpiece and a wire electrode includes: a machining current setting unit for setting the magnitude of a normal machining current depending on the discharge gap state at application of a discharge induction voltage at the previous time or previous times; and a machining current control unit configured to control a main discharge circuit so as to supply the normal machining current to the discharge gap when the present discharge gap state is the normal state, control the main discharge circuit so as to supply a short-circuit machining current smaller than a predetermined current to the gap when the discharge gap state is the short-circuited state, and control the main discharge circuit so as not to supply any machining current to the gap when the discharge gap state is the open state.