Wire Electrical Discharge Machining Power Feed Contacts
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Solution Overview
Problem
In multi-wire electrical discharge machining, uneven power supply to wires results in defective grooves, as some wires may not receive adequate power, leading to inconsistencies in machining quality.
Innovation Solution
A wire electrical discharge machining system with a traveling unit and power feed contacts that collectively supply machining power to multiple wires, ensuring equal power distribution by arranging adjacent power feed contacts off-vertical to the wire travel direction, allowing for uniform electrical discharge machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power is collectively supplied to multiple wires at one place, then the device complexity is reduced, but the manufacturing precision deteriorates due to uneven power distribution to wires
Solution Approach 1:
The power feed contacts are segmented into multiple separate contacts instead of using a single collective contact. This segmentation allows each wire to receive power from its own dedicated contact point, ensuring uniform power distribution while maintaining a relatively simple overall structure. The segmentation resolves the contradiction by dividing the power supply function into discrete units that can be individually optimized for each wire.
Solution Approach 2:
Each wire is provided with locally optimized power feed contact positioning, where the contacts are arranged at specific locations along the wire path. This local quality approach ensures that each wire receives adequate power at its specific location, preventing the power distribution unevenness that would occur with a single collective contact point, thereby maintaining high groove uniformity across all wires.
2Productivity
If wires are arranged side by side at equally spaced intervals, then the productivity is improved by parallel machining, but the reliability deteriorates due to power supply instability to individual wires
Solution Approach 1:
The power supply system is segmented to provide dedicated power feed contacts for each wire in the parallel arrangement. This segmentation ensures that each wire maintains stable and reliable power supply independently, preventing the power instability that would occur with collective power supply, while still enabling high-productivity parallel machining of multiple wires simultaneously.
Solution Approach 2:
The power feed contacts act as intermediary elements between the power source and each individual wire. These intermediaries ensure stable power transmission to each wire by providing dedicated contact points that compensate for variations in wire position and tension, thereby maintaining reliable power supply across all parallel wires during high-speed machining operations.
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 reduces the number of underpowered wires and achieves high uniformity in electrical discharge machining, maintaining machining quality across all wires, even when power is collectively supplied to multiple wires.
Implementation Method 1
a power feed contact configured to collectively supply a machining power supply to a plurality of the traveling wires
Implementation Method 2
wire electrical discharge machining system configured to slice a workpiece
Data Source
AI summary
A mechanism capable of decreasing wires which are not appropriately supplied with power and performing the electrical discharge machining high in uniformity between multiple wires. A wire electrical discharge machining system configured to slice a workpiece at an interval of wires arranged side by side at equally spaced intervals causes the wire to travel in the same direction and includes a power feed contact configured to collectively supply a machining power supply to a plurality of the traveling wires, in which two adjacent power feed contacts respectively come into contact with the plurality of the wires supplied with the machining power supply and arranged without being aligned in the direction vertical to the direction in which the wire travels.