Wire Electric Discharge Machine Interference Prevention
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Solution Overview
Problem
Conventional wire electric discharge machines face issues with erroneous machining due to interference between the wire electrode and the workpiece table or jig, leading to ineffective use of the operating range, as the existing stroke limit setting methods fail to accurately prevent collisions during taper machining.
Innovation Solution
A wire electric discharge machine equipped with an interference determination unit that calculates the position of the wire electrode and checks for interference with the workpiece table and jig surfaces, allowing for virtual execution of machining programs to prevent collisions and optimize the operating range by determining safe distances and selecting relevant surfaces to check for interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stroke limit setting methods are used, then the machine structure is simple and easy to operate, but interference between the wire electrode and workpiece table or jig occurs during taper machining, causing erroneous machining
Solution Approach 1:
The interference determination unit performs preliminary checks before machining by calculating the position of the wire electrode and determining whether it interferes with the workpiece table or jig surfaces. This preliminary action prevents erroneous machining by identifying potential interference issues before they occur during actual machining operations.
Solution Approach 2:
The system creates a virtual model of the machining process by calculating wire electrode positions and checking for interference with workpiece table and jig surfaces. This copying approach allows the system to simulate and detect potential interference without requiring physical trial runs, thereby preventing erroneous machining while maintaining operational simplicity.
2Reliability
If stroke limits are set to prevent interference, then erroneous machining is reduced, but the operating range of the machine is reduced, leading to ineffective use of capabilities
Solution Approach 1:
The interference determination unit dynamically adjusts the effective stroke limits based on the actual machining conditions, wire electrode position, and workpiece configuration. Instead of using fixed conservative limits, the system calculates real-time interference-free boundaries, allowing the machine to operate across its full capable range while preventing erroneous machining.
Solution Approach 2:
The system changes the parameters defining the operating range by calculating dynamic interference boundaries based on wire electrode position, workpiece table location, and jig configuration. This allows the machine to expand its effective operating range while maintaining reliability by adjusting the parameters that define safe machining boundaries.
3Reliability
If comprehensive interference checking is performed for all surfaces, then prevention of erroneous machining is improved, but calculation load increases
Solution Approach 1:
The interference determination unit applies local quality checking by focusing interference detection only on relevant surfaces such as the workpiece table top surface and jig surfaces that are actually at risk during taper machining. Instead of checking all possible surfaces uniformly, the system selectively checks only those areas where interference is possible, reducing calculation load while maintaining reliable prevention of erroneous machining.
Data Source
AI summary
A wire electric discharge machine performs electric discharge machining on a workpiece by relatively moving a workpiece placed on a workpiece table and a wire electrode supported by upper and lower wire guides according to a machining program. The wire electric discharge machine comprises an interference determination unit configured to determine whether or not the top or bottom surface of the workpiece table interferes with the wire electrode at the height of the surface during the execution of the machining program.