Wire EDM Power Feeding Jig Reference Surfaces

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Solution Overview

Problem

Conventional wire electric discharge machining systems face issues with cumulative errors and labor-intensive adjustments due to dimension errors in insulators and slidable contact conductors, requiring frequent fine adjustments and increased labor for maintenance as the number of cutting wires increases.

Innovation Solution

A wire electric discharge machining apparatus with a power feeding jig that individually holds and positions slidable contact conductors using reference surfaces to prevent cumulative errors, allowing for precise power feeding without the need for frequent adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an integral structure with alternately laminated insulators and slidable contact conductors is used, then power feeding is achieved, but cumulative errors occur in positioning due to dimension errors in components

Engineering Contradiction:

Improvepower feeding stabilityVSAvoidpositioning accuracy of slidable contact conductors

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The power feeding unit is divided into modular components: individual insulator units (23a-23d), separate slidable contact conductors (31a-31d), and a base structure (22). Each slidable contact conductor can be independently positioned and adjusted on its respective insulator, eliminating cumulative positioning errors that would occur in an integral laminated structure. This segmentation allows each component to be manufactured and positioned independently with its own reference surfaces.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the number of cutting wires is increased, then collective cutting capability is improved, but the number of slidable contact conductors increases requiring more labor for adjustment

Engineering Contradiction:

Improvecollective cutting capabilityVSAvoidlabor for adjustment and maintenance

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system uses individual slidable contact conductors (31a-31d) for each cutting wire, allowing independent adjustment. When maintenance is needed, only the specific conductor requiring adjustment needs to be accessed, rather than adjusting all conductors in an integral structure. This reduces maintenance labor proportionally as the system scales to more cutting wires.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The slidable contact conductors are designed with self-positioning capabilities through reference surfaces and guide structures. The conductors can slide into their correct positions on the insulators without requiring complex external adjustment mechanisms, reducing the skill level and time required for maintenance operations.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If fine adjustment of intervals between slidable contact conductors is performed during assembly, then positioning accuracy is improved, but assembly time and labor increase

Engineering Contradiction:

Improvepositioning accuracyVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Reference surfaces are pre-formed on the insulators (23a-23d) and slidable contact conductors (31a-31d) during manufacturing. These reference surfaces establish the correct intervals and positions in advance. During assembly, the components simply need to be brought together and the reference surfaces will automatically ensure correct positioning, eliminating the need for time-consuming fine adjustment operations during assembly.

Inventive Principle:

Principle #10Preliminary action

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

The solution effectively prevents cumulative errors in slidable contact conductor positioning, reducing labor requirements and maintaining satisfactory power feeding even with dimension errors, thus enhancing the efficiency and reliability of the machining process.

Implementation Method 1

generating a discharge between the wire electrodes arranged in parallel and the workpiece

Methodology Applied

Scientific EffectElectrical discharge: Electric Spark

Implementation Method 2

wire electric discharge machining apparatus

Methodology Applied

Scientific EffectElectrical discharge machining: Electrical Discharge Machining

Data Source

PatentUS9089916B2Wire electric discharge machining apparatus, wire electric discharge machining method, thin plate manufacturing method, and semiconductor wafer manufacturing method

Publication Date: 2015.07.28 MITSUBISHI ELECTRIC CORP

AI summary

A wire electric discharge machining apparatus includes a wire electrode, a guide roller that arranges wire electrodes in parallel by winding the wire electrode therearound, a plurality of slidable contact conductors that are in slidable contact with the wire electrodes arranged in parallel, respectively, and a power feeding jig that holds the slidable contact conductors individually and feeds power individually to the wire electrodes arranged in parallel via each of the slidable contact conductors, in which the power feeding jig includes a plurality of reference surfaces that determine a fixing interval between the slidable contact conductors.