Wire EDM Fulcrum Position Calculation for Faster Taper Setup
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Solution Overview
Problem
Existing methods for determining fulcrum positions in wire electric discharge machines are time-consuming due to the need for repeated measurements when wire guides are replaced or adjusted, affecting the accuracy and efficiency of taper machining.
Innovation Solution
A method and device that utilize a controller to acquire and store relative fulcrum positions for different angles, allowing for rapid calculation of fulcrum positions by measuring and calculating based on stored data, reducing the need for repeated measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fulcrum positions are determined by repeated measurements for each angle after wire guide replacement, then measurement accuracy is improved, but time consumption increases
Solution Approach 1:
The patent pre-calculates and stores relative position data between fulcrum positions at different angles before wire guide replacement occurs. When replacement happens, the system retrieves these pre-stored relative position relationships and applies them to calculate new fulcrum positions based on a single reference measurement, eliminating the need for repeated measurements at each angle and significantly reducing time consumption while maintaining accuracy.
Solution Approach 2:
The patent creates a computational model that copies the relative position relationships between fulcrum positions at different angles. Instead of physically remeasuring each position, the system uses the stored relative position data to generate accurate fulcrum position information for multiple angles through calculation, effectively creating a virtual copy of the measurement data that can be rapidly retrieved and applied.
2Measurement precision
If fulcrum positions are determined by measurement at each angle, then position accuracy is improved, but operational efficiency deteriorates
Solution Approach 1:
The system performs preliminary calculations of relative fulcrum position relationships and stores them in advance. During actual machining setup after wire guide replacement, only a single reference fulcrum position needs to be measured, and the system automatically calculates positions at all required angles using the pre-stored relative position data, dramatically improving setup efficiency without sacrificing measurement accuracy.
Solution Approach 2:
The patent changes the approach from direct measurement of absolute positions at each angle to measuring a single reference position and calculating others based on stored relative position parameters. This parameter transformation allows the system to maintain high positional accuracy while reducing the number of measurements required, thereby improving overall productivity.
Data Source
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Figure 3A~3B
AI summary
A fulcrum position calculation method according to the present invention is used to calculate a fulcrum position of a wire electrode of a wire electric discharge machining machine and includes: acquiring a relative position from a storage unit in which is stored the relative position between a fulcrum position corresponding to a first angle, which is the angle of inclination of the wire electrode, and a fulcrum position corresponding to each of a plurality of angles differing from the first angle; inclining the wire electrode to the first angle; measuring the fulcrum position corresponding to the first angle; and calculating the fulcrum position corresponding to each angle on the basis of the relative position and the measured fulcrum position corresponding to the first angle.