Wire Electric Discharge Machine With Multijoint Robot

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Solution Overview

Problem

Conventional wire electric discharge machining requires frequent interruptions and significant labor to change the posture of the workpiece for performing 2D machining or polyhedral shapes over 2.5D machining, limiting the degree of freedom and increasing cycle time.

Innovation Solution

A wire electric discharge machine equipped with a multijoint robot and a wire crossing mechanism that allows for the controlled movement and posture adjustment of the wire electrode, enabling machining without changing the workpiece posture by synchronizing the robot's movements with the machine's axes through a controller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional wire electric discharge machining is performed with fixed wire electrode orientation, then machining simplicity is maintained, but the degree of freedom for machining various surfaces is limited

Engineering Contradiction:

Improvedegree of freedom for machining various surfacesVSAvoidmachining system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The wire electrode support structure is transformed from a fixed configuration to a dynamic one, where the wire crossing mechanism can be repositioned along the wire electrode's length and the wire electrode itself can be tilted at various angles. This dynamic adaptability allows the same machining system to handle diverse surface geometries without requiring multiple fixed setups.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention introduces additional degrees of freedom by enabling the wire electrode to operate not only in a vertical plane but also at tilted angles and with lateral positioning adjustments. This multi-dimensional movement capability allows the wire electrode to access and machine complex three-dimensional surfaces that would be inaccessible with conventional fixed-orientation wire discharge machining.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If workpiece posture is changed for 2D or polyhedral machining, then machining capability is improved, but machining time and labor increase significantly

Engineering Contradiction:

Improvemachining capability for 2D and polyhedral shapesVSAvoidmachining cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Instead of changing the workpiece posture to achieve different machining orientations, the invention inverts the approach by keeping the workpiece stationary and changing the orientation and position of the wire electrode through the adjustable wire crossing mechanism and tilted wire electrode support. This eliminates the need for time-consuming workpiece repositioning and setup changes.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The wire crossing mechanism enables continuous machining operations by allowing the wire electrode to be repositioned and reoriented without interrupting the machining process. The mechanism can adjust the wire's position and angle on-the-fly, maintaining continuous productive action rather than requiring stoppages for posture changes.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If wire electrode position is fixed for simple 2D machining, then operation simplicity is maintained, but flexibility for complex surface machining is reduced

Engineering Contradiction:

Improveoperation simplicityVSAvoidflexibility for complex surface machining

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The wire electrode support system is segmented into independently controllable components: the wire crossing mechanism that can be positioned along the wire's length, and the tilted wire electrode support that can angle the wire. This segmentation allows each component to be adjusted independently, providing fine-grained control for complex surfaces while maintaining simple operation through automated coordination.

Inventive Principle:

Principle #1Segmentation

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 high-degree-of-freedom machining for 2D and 2.5D shapes without altering the workpiece posture, reducing labor and cycle time by allowing continuous operation and increased flexibility in wire electrode orientation.

Implementation Method 1

causing an electric discharge phenomenon between a conductive wire electrode and the work thereby to melt and scatter part of the work

Methodology Applied

Scientific EffectElectric discharge phenomenon: Electrical Discharge Machining

Data Source

PatentUS10086456B2Wire electric discharge machine capable of machining various surfaces

Publication Date: 2018.10.02 FANUC LTD

AI summary

A wire electric discharge machine according to the present invention includes a multijoint robot including a wire crossing mechanism for crossing a wire electrode on its tip end, a robot controller for controlling the multijoint robot, a numerical controller for controlling the wire electric discharge machine, and a transmission unit for transmitting a coordinate position when the multijoint robot is driven and controlled to move the wire crossing mechanism from the robot controller to the numerical controller, and the numerical controller synchronizes a position of each shaft of the wire electric discharge machine with a movement of the wire crossing mechanism with reference to the coordinate position transmitted by the transmission unit.