Wire Electric Discharge Machine Remaining Length Calculation
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Solution Overview
Problem
Existing wire electric discharge machines face increased margin of error in estimating the remaining length of wire electrodes as they become shortened, leading to inaccurate calculations.
Innovation Solution
A wire electric discharge machine equipped with a remaining length calculation unit that uses electrode winding coefficients, bobbin draw-out radius correlation information, and spool diameter to accurately estimate the remaining wire electrode length, incorporating a functional block diagram and flowchart for the calculation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the remaining length is calculated by subtracting delivered length from total length, then the calculation method is simple, but the measurement precision deteriorates as the remaining wire becomes shorter
Solution Approach 1:
The patent changes the calculation parameters from simple length subtraction to using bobbin draw-out radius correlation information. By measuring the bobbin draw-out radius (distance from wire separation point to bobbin rotation axis) and using pre-stored correlation data between radius and remaining length, the system achieves accurate remaining length estimation regardless of how much wire has been consumed. This parameter transformation resolves the contradiction by maintaining high precision without excessive complexity.
2Ease of manufacture
If the margin of error is kept constant in absolute terms, then the calculation is straightforward, but the reliability of machining decisions decreases when remaining wire is short
Solution Approach 1:
The patent replaces the mechanical subtraction-based calculation system with a measurement-based system using bobbin draw-out radius. By substituting the calculation mechanism with a physical measurement (radius) and lookup operation (correlation information), the system maintains ease of implementation while dramatically improving reliability for machining decisions when wire remains short.
Data Source
AI summary
A wire electric discharge machine for machining a workpiece by causing a discharge between a wire electrode delivered from a wire bobbin and the workpiece. The wire electric discharge machine includes: a remaining length calculation unit that calculates a remaining length of the wire electrode based on electrode winding coefficients, bobbin draw-out radius correlation information, and a spool diameter of the wire bobbin. The electrode winding coefficients depend on a winding density of the wire electrode, an inner width of the wire bobbin, a wire diameter of the electrode wire, and a winding tension of the wire electrode. The bobbin draw-out radius correlation information is correlated with a bobbin draw-out radius that is a distance between a position at which the wire electrode wound around the wire bobbin is separated from the wire bobbin and a central axis of rotation of the wire bobbin.