Wire EDM Guide Alignment Using Thermal Displacement Learning
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Solution Overview
Problem
Existing wire electric discharge machines face challenges in maintaining machining precision due to thermal deformation of machine elements, which is exacerbated by changes in the installation environment, and current correction methods are either inefficient or require significant capital investment for temperature control or rely on static correction equations.
Innovation Solution
The implementation of a data sharing and machine learning-based system that calculates thermal displacement correction amounts using a multi-layered neural network, allowing for dynamic adjustment of relational expressions to account for varying installation environments, ensuring accurate positioning of upper and lower guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal displacement correction is performed using static correction equations, then machining precision can be maintained under stable installation conditions, but the system cannot adapt when installation environment changes occur
Solution Approach 1:
The patent transforms the static correction equation into a dynamic system by introducing machine learning models that continuously learn and update correction parameters based on actual machining data and environmental conditions. The correction amount is no longer fixed but dynamically adjusted according to real-time temperature sensors and machining outcomes, enabling the system to adapt to changing installation environments while maintaining precision.
Solution Approach 2:
The patent implements a feedback mechanism where machining results and temperature data are continuously monitored and fed back to update the correction equations. The system uses detected machining precision and environmental conditions to iteratively refine correction parameters, creating a closed-loop system that self-adjusts to maintain accuracy under varying installation conditions.
2Manufacturing precision
If temperature-controlled rooms are installed to prevent thermal deformation, then machining precision can be maintained, but capital investment and operational costs increase significantly
Solution Approach 1:
The patent replaces the mechanical/physical temperature control system with an information-processing-based thermal displacement correction system. Instead of actively controlling temperature through HVAC equipment, the system uses temperature sensors and machine learning algorithms to calculate and compensate for thermal effects computationally, substituting physical temperature control with intelligent software-based correction.
Solution Approach 2:
The patent changes the approach from controlling the physical parameter (temperature) to controlling the computational parameter (correction amount). By transforming the problem from thermal management to mathematical compensation, the system achieves precision maintenance without the energy costs of active temperature control, using parameter transformation rather than physical intervention.
3Manufacturing precision
If correction equations are recalculated by repeating measurements after installation, then accuracy for specific environments can be improved, but work hours and measurement time increase
Solution Approach 1:
The patent performs preliminary thermal displacement measurements and correction equation development during the factory setup phase, before the machine is installed at the customer site. By completing extensive measurements and model training in advance, the system establishes a baseline correction model that can be quickly deployed and fine-tuned at the installation location, minimizing on-site measurement time and work hours.
Solution Approach 2:
The patent enables the correction system to self-improve through continuous learning from actual machining data. Once deployed, the system automatically collects temperature and machining result data, and the machine learning model continuously refines correction parameters without requiring manual intervention or repeated measurements by operators, making the system self-optimizing over time.
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 enables continuous and effective thermal displacement correction, even with changes in the installation environment, thereby maintaining machining precision without the need for extensive temperature control measures or work hours, and allows for the derivation of a universally applicable correction equation.
Implementation Method 1
the thermal expansion coefficients of these machine elements differ from each other. Therefore, due to factors such as a change in the temperature of the environment, there is concern over a plurality of machine elements thermally deforming
Data Source
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AI summary
To provide a wire electric discharge machine which can appropriately perform thermal displacement correction of upper/lower guides even when the installation environment changes. Provided are a storage unit (21) that stores temperatures of machine elements as temperature data, and a rendering unit (22) that digitizes the installation environment and renders as environmental data. Additionally provided are a position command unit (23) that commands a relative position of the upper/lower guides; and a relational expression calculation unit (24) that sets the temperature data environmental data as input data, sets the relative position as training data, and calculates the relational expression by way of machine learning. Further provided are a relational expression decision unit (29) that calculates a correction amount by substituting the temperature of the machine element into this relational expression, and in the case of error between the relative position of the upper/lower guides based on this correction amount and the relative position commanded by the position command unit (23) being small, decides this relational expression as a formal relational expression; and a correction execution unit (25) that performs correction on the relative position of the upper/lower guides using this relational expression.