Wire EDM Discharge Position Detection for Real-Time Arc Concentration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire electric discharge machining technologies face challenges in detecting concentrated electric discharge in real-time and accurately determining the discharge position, leading to potential electrode breakage and reduced machining accuracy due to external disturbances.
Innovation Solution
A wire electric discharge machine and method that utilize an auxiliary power supply for preliminary discharge current and a main power supply for main discharge current, with current detectors and a discharge position calculation circuit to detect the discharge position during two distinct periods, allowing for early detection of concentrated electric discharge and improved accuracy in plate thickness measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the discharge position is detected using the preliminary discharge current delayed by 150 ns to 300 ns from the initial stage of electric discharge, then the detection is less affected by external disturbances, but the detection timing is delayed and real-time detection of concentrated electric discharge is compromised
Solution Approach 1:
The patent applies preliminary action by performing discharge position detection at two distinct phases: first during the rising period (first period) to enable real-time concentrated discharge detection, and second during the steady period (second period) to obtain accurate discharge position for plate thickness measurement. This preliminary detection during both periods allows the system to prepare and respond to concentrated electric discharge events without delay while maintaining measurement accuracy.
2Loss of time
If the discharge position is detected immediately after electric discharge starts, then real-time detection of concentrated electric discharge is enabled, but the detection accuracy is reduced due to external disturbances such as stray capacitance and stray inductance
Solution Approach 1:
The system performs preliminary discharge position detection during the rising period of the preliminary discharge current (first period) to enable real-time concentrated discharge detection, and then performs additional detection during the steady period (second period) to obtain accurate discharge position data for plate thickness measurement. This two-stage preliminary action ensures both real-time response and measurement accuracy.
Solution Approach 2:
The patent uses the preliminary discharge current as an intermediary to detect discharge position indirectly through current distribution patterns between upper and lower conductors, rather than directly measuring the discharge point. This intermediary approach allows detection during both rising and steady periods, bridging the gap between real-time detection needs and measurement accuracy requirements.
3Reliability
If concentrated electric discharge is detected and main discharge voltage is stopped in real-time, then electrode breakage is prevented, but the processing time for detecting and responding to concentrated discharge increases
Solution Approach 1:
The system performs preliminary discharge position detection during the rising period (first period) of the preliminary discharge current, which occurs immediately after electric discharge starts. This preliminary detection enables the system to identify concentrated electric discharge events and stop the main discharge voltage in real-time, preventing electrode breakage while minimizing processing delay.
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 real-time detection of concentrated electric discharge, reduces electrode wear, and enhances the accuracy of plate thickness calculations by minimizing the influence of external disturbances.
Implementation Method 1
a voltage for inducing generation of electric discharge is applied to a machining gap formed between a wire electrode and a workpiece
Implementation Method 2
a voltage pulse to a machining gap formed between a wire electrode and a workpiece to continuously generate electric discharge and perform machining with the discharge energy
Implementation Method 3
a current detector detecting a discharge current flowing between the machining gap and a pair of conductors that are respectively provided above and below the workpiece
Data Source
AI summary
The disclosure provides a wire electric discharge machine and a wire electric discharge machining method capable of detecting concentrated electric discharge in real time by a discharge position obtained from a preliminary discharge current, and calculating an accurate discharge position for use in measuring a plate thickness or the like. The wire electric discharge machine according to the disclosure includes a discharge position calculation circuit calculating a discharge position from the preliminary discharge current respectively detected through a current detector during a first period from a time when a waveform of the preliminary discharge current supplied to a machining gap, formed by a wire electrode and a workpiece, rises to a time when the preliminary discharge current reaches a constant current value, and a second period after the time when the preliminary discharge current reaches the constant current value to a time when a main discharge current is supplied.