Wire EDM Disconnection Repairing Unit for Automatic Connection
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Solution Overview
Problem
Conventional wire electric discharge machines face challenges in resuming machining after disconnection occurs due to the accumulation of deposits in the core fixing section, which prevents automatic connection and restart of machining.
Innovation Solution
A wire electric discharge machine with a disconnection repairing unit that performs automatic connection between the disconnection position and the core fixing end position, using electric discharge machining to deposit and accumulate machining wastes and control moving axes to resume machining, while determining the presence of an automatic connection position between the disconnection and core fixing end positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the core fixing function is used to accumulate deposits in the machining groove, then the core is fixed to the workpiece and machining efficiency is improved, but automatic connection becomes disabled when the wire electrode reaches the core fixing portion while retracting
Solution Approach 1:
The system performs preliminary action by storing the core fixing end position during the machining process. When disconnection occurs, this pre-stored position information enables the wire to retract to a valid connection position before reaching the problematic core fixing section, thus preventing connection failure while maintaining the core fixing function's productivity benefits
Solution Approach 2:
The control unit acts as an intermediary by introducing a position monitoring and decision-making mechanism. It compares the wire's retraction position with the stored core fixing end position, and only permits connection when the wire is at a safe distance from the core fixing section, thus mediating between the need for automatic connection and the presence of deposits in the machining groove
2Ease of operation
If the wire electrode retracts to perform automatic connection after disconnection, then the machining can be resumed, but the wire may reach the core fixing section where deposits prevent successful connection
Solution Approach 1:
The system implements feedback by continuously monitoring the wire's position during retraction and comparing it with the stored core fixing end position. The control unit provides feedback signals to determine whether the wire has reached a safe position for connection, ensuring that connection only occurs when the wire is at an appropriate distance from the core fixing section with accurate position control
3Ease of manufacture
If conventional processes are used to cut off the core after machining, then the core can be removed, but additional machining steps are required increasing machining time
Solution Approach 1:
The invention extracts the core removal operation from the traditional multi-step process. By using the core fixing deposits themselves as the removal mechanism, the system eliminates the need for separate stock removal sections and additional electric discharge machining steps, thereby reducing machining time while maintaining ease of core removal through simple external force application
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 automatic connection and resumption of machining on a machined route after disconnection, improving machining efficiency by avoiding retraction issues caused by core fixing sections, thereby reducing downtime and enhancing operational reliability.
Implementation Method 1
electric discharge machining of a workpiece with electric discharge generated between the wire electrode and the workpiece
Implementation Method 2
depositing and accumulating machining wastes caused by the electric discharge machining to thereby fix a core generated by the electric discharge machining and the workpiece
Data Source
AI summary
A wire electric discharge machine provided with a disconnection repairing unit includes a core-fixing-end-position storing unit for storing a core fixing end position of a depositing and accumulating operation machined most lately among positions at which the depositing and accumulating operation for machining wastes by a core fixing function ends in a machining shape currently being machined and a disconnection repairing unit for executing automatic connection between a disconnection position and the core fixing end position.