Wire EDM End Surface Detection Using Filtered Voltage Position Data
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Solution Overview
Problem
Existing wire electrical discharge machines face accuracy issues in detecting the position of objects on a work table due to factors like oil films, sludge, and wire electrode bending, leading to decreased detection precision.
Innovation Solution
A wire electrical discharge machine with a voltage detection unit, determination unit, relative movement control unit, storage control unit, data extraction unit, and end surface position determination unit that performs multiple detection operations, stores relative positions, extracts valid data within a predetermined range, and determines the object's end surface position based on this data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the wire electrode is brought into contact with the placed object to detect position, then the detection method is simple, but the detection accuracy decreases due to oil films, sludge, or wire electrode bending
Solution Approach 1:
The patent replaces the mechanical contact-based detection method with an electrical field-based detection method. Instead of relying on physical contact between the wire electrode and the placed object, the system applies voltage between the wire electrode and the object and detects voltage changes to determine contact status and position. This eliminates the problems caused by oil films, sludge, and wire electrode bending that affect mechanical contact detection accuracy.
2Measurement precision
If multiple detection operations are performed to improve accuracy, then the position detection accuracy improves, but the detection time increases
Solution Approach 1:
The patent performs multiple end surface detection operations in advance before the actual machining operation. By conducting these preliminary detection operations, the system collects multiple measurement data points and uses statistical processing to determine the most accurate end surface position. This preliminary action ensures high accuracy is achieved before production begins, preventing rework and ensuring quality from the start.
Solution Approach 2:
The patent implements a feedback mechanism where multiple voltage detection results are collected and processed. The system compares multiple detection results, identifies valid data within a predetermined range, and uses this feedback to determine the final end surface position. This feedback loop allows the system to filter out erroneous measurements and converge on the accurate position despite variations in individual measurements.
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
This approach enhances the accuracy of object position detection by filtering out errors and stabilizing the inter-electrode voltage, improving the precision of end surface position determination.
Implementation Method 1
a voltage detection unit configured to detect a voltage between the wire electrode and the placed object
Data Source
AI summary
This wire elective discharge machine includes: a relative movement control unit that performs an end surface detection operation a predetermined number of times; a storage control unit that stores, in a storage unit, a relative location of a wire electrode to a workpiece table when it is determined that a wire electrode is in contact with a workpiece in each end surface detection operation; and a data extraction unit that extracts, as effective data, a plurality of relative locations located in the order of a predetermined range in a middle when the plurality of relative locations are arranged in ascending order; and an end surface location determination unit that determines the location of an end surface of the workpiece on the basis of the effective data.