Wire EDM Control for Deviated Wire Feeding Hole Position
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Solution Overview
Problem
Existing wire electrical discharge machines require manual intervention when the wire feeding hole position deviates from the programmed position, leading to increased operator burden and reduced productivity due to the inability to perform continuous automatic operation.
Innovation Solution
A wire electrical discharge machine equipped with a wire feeding control unit, machining control unit, imaging unit, and wire feeding hole position acquisition unit that automatically adjusts the wire electrode's position and continues machining even when the wire feeding hole is deviated from the programmed position, using imaging to accurately determine the wire feeding hole's position and performing electrical discharge machining along a path segment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual wire electrode feeding is performed when wire feeding hole position deviates from programmed position, then wire electrode can be fed, but operator burden increases and continuous automatic operation cannot be achieved
Solution Approach 1:
The system automatically detects wire feeding hole position deviation using an imaging unit and autonomously adjusts the wire electrode feeding position and machining path without operator intervention. The control unit modifies the machining program to accommodate the actual hole position, enabling the system to serve itself and maintain continuous automatic operation.
Solution Approach 2:
The imaging unit captures images of the wire feeding hole position and feeds this information back to the control unit. The control unit compares the actual position with the programmed position and automatically adjusts the wire electrode feeding and machining path accordingly, creating a closed-loop feedback system that maintains productivity.
2Manufacturing precision
If manual intervention is required for wire feeding when hole position deviates, then positioning accuracy can be adjusted, but operation time increases and productivity decreases
Solution Approach 1:
The system replaces manual mechanical positioning with an automated imaging and control system. The imaging unit optically detects the wire feeding hole position, and the control unit automatically calculates and executes the position correction, substituting manual mechanical adjustment with automated optical-mechanical control to reduce operation time while maintaining precision.
Solution Approach 2:
The system performs preliminary detection of the wire feeding hole position using the imaging unit before wire electrode feeding begins. By detecting and compensating for position deviation in advance, the system prevents operation delays and maintains both precision and efficiency.
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 continuous automatic operation and improved productivity by allowing auto wire feeding and machining even when the wire feeding hole position differs from the programmed position, reducing manual intervention and downtime.
Implementation Method 1
an imaging unit (28) configured to take an image of the workpiece (14)
Implementation Method 2
a machine main body (31) for performing electrical discharge machining on a workpiece (14) with a wire electrode (12)
Data Source
AI summary
A wire electrical discharge machine includes a wire feeding hole position acquisition unit configured to obtain a position of a wire feeding hole that allows for insertion and feeding of a wire electrode. In this wire electrical discharge machine, when the position of the wire feeding hole obtained by the wire feeding hole position acquisition unit is deviated from a wire feeding position defined by a machining program, a wire feeding control unit controls a machine main body to move the wire electrode to the position of the wire feeding hole and feed the wire electrode there, and a machining control unit controls the machine main body to perform electrical discharge machining on a workpiece with the wire electrode while moving the wire electrode on a path segment between a position where the wire electrode has been fed and the wire feeding position defined by the machining program.