Wire Electrical Discharge Machine Reference Position Compensation
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Solution Overview
Problem
Existing wire electrical discharge machines face challenges in accurately and quickly determining the reference position due to unstable detection voltage changes caused by wire electrode vibration, leading to errors in contact and non-contact state detection, which are exacerbated by high moving speeds and sampling periods.
Innovation Solution
A wire electrical discharge machine equipped with a voltage applying unit, relative movement unit, contact state detecting unit, wire electrode position detecting unit, and end face determination position compensation unit, which applies detection voltage, moves the wire electrode relative to the workpiece, detects contact and non-contact states, and compensates for displacement errors using stored wire electrode diameter and displacement amounts to accurately determine the reference position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire electrode and workpiece are relatively moved at high speed to quickly determine the reference position, then the productivity is improved, but the detection accuracy deteriorates due to vibration-induced unstable voltage changes
Solution Approach 1:
The system continuously monitors the detection voltage between the wire electrode and workpiece during relative movement, using real-time feedback to identify the contact state. The control unit adjusts the detection based on voltage changes, enabling accurate contact position determination even at high movement speeds where vibration occurs.
Solution Approach 2:
The invention changes the detection parameter from relying on stable mechanical contact to monitoring electrical voltage changes. By detecting voltage transitions between contact and non-contact states, the system can accurately determine reference positions without being affected by mechanical vibration, thus maintaining measurement precision at high productivity.
2Loss of time
If the wire electrode is moved quickly through the workpiece to reduce detection time, then the loss of time is reduced, but the reliability of contact state detection deteriorates due to vibration
Solution Approach 1:
The invention replaces mechanical contact detection with electrical field detection. By using voltage application and detection between the wire electrode and workpiece, the system eliminates the need for stable mechanical contact, thereby maintaining detection reliability even during high-speed movement when vibration occurs.
Solution Approach 2:
The system uses continuous voltage feedback during the quick movement process to reliably detect contact states. The control unit monitors voltage changes in real-time, enabling accurate determination of contact/non-contact states regardless of movement speed or vibration, thus maintaining both speed and reliability.
3Measurement precision
If multiple detection positions are averaged to improve accuracy, then the measurement precision is improved, but the device complexity increases due to additional detection and calculation requirements
Solution Approach 1:
The control unit serves multiple functions: it controls the relative movement, applies detection voltage, monitors voltage changes, determines contact states, calculates multiple detection positions, and computes the averaged reference position. This multi-functionality avoids adding separate complex detection systems while achieving improved measurement precision through averaging.
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 quicker and more accurate determination of the reference position by averaging multiple detection positions and compensating for displacement errors, reducing the impact of vibration and moving speed on detection accuracy.
Implementation Method 1
a detection voltage is applied between the wire electrode and the workpiece and the transition of the difference in the detection voltage corresponding to contact and/or non-contact is detected
Implementation Method 2
a wire electrode and an object of positioning/measurement are relatively moved to contact each other, in order to ascertain their relative positions
Data Source
AI summary
A wire electrical discharge machine for detecting an end face of an object, configured so that when a contact detection movement is started and if contact between the wire electrode and the workpiece is detected, positions in which the contact between the wire electrode and the workpiece is detected are stored as contact detection positions and that when a non-contact detection movement is then started and if non-contact between the wire electrode and the workpiece is detected, positions in which the non-contact between the wire electrode and the workpiece is detected are stored as non-contact detection positions. When it is determined whether or not a set number of times of execution is reached and if the set number of times of execution is reached, a reference position is obtained by adding the radius of the wire electrode and a clearance of the wire guide to an end face determination position.