Wire EDM Reference Positioning to Avoid Sensor Collisions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for controlling wire electric discharge machines struggle to accurately position machining reference parts without collisions between the workpiece and measuring units, leading to errors in shape accuracy and tool performance.
Innovation Solution
A method is introduced that includes a positioning unit for the machining reference part and a measuring unit to detect and measure errors, using a vision sensor to determine the position of the machining reference part and prevent collisions, ensuring accurate positioning and measurement without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the workpiece is positioned without preliminary detection, then the positioning process is simple and fast, but the measurement accuracy deteriorates due to collisions between the workpiece and measuring unit
Solution Approach 1:
The patent applies preliminary action by using a vision sensor to detect the position of the machining reference part before the actual measurement process. This preliminary detection allows the system to pre-position the workpiece or adjust the measuring unit's path to avoid collisions, thereby ensuring measurement accuracy without adding significant complexity to the overall process.
2Productivity
If the touch sensor is moved to the measurement position at high speed, then the measurement process is faster, but the collision risk between the sensor and workpiece increases
Solution Approach 1:
The patent implements feedback by using the vision sensor to continuously monitor the workpiece position and provide real-time information to the control system. This feedback mechanism allows the system to dynamically adjust the touch sensor's movement path and speed, maintaining high productivity while reliably avoiding collisions through continuous position verification.
3Manufacturing precision
If the machining reference part is not pre-positioned, then the setup process is simpler, but the shape accuracy of the workpiece deteriorates due to positioning errors
Solution Approach 1:
The patent replaces the traditional mechanical positioning system with a vision-based detection and positioning system. The vision sensor optically detects the machining reference part's position and provides data to the control system, which then automatically adjusts the workpiece position. This substitution eliminates complex mechanical adjustment mechanisms while achieving high positioning accuracy and reducing manual intervention time.
Data Source
Figure 1~2(b)
Figure 3~4(b)
Figure 5~6
AI summary
Provided is a wire electric discharge machine in which workpiece attaching and detaching unit attaches and detaches a workpiece to and from workpiece fixing unit, machining-reference-part detecting unit detects the position of a machining reference part of the workpiece, workpiece-positioning executing unit positions the workpiece in a position where the workpiece does not collide with machining-reference-part measuring unit, measurement-positioning executing unit positions the machining-reference-part measuring unit in a predetermined measurement start position, the machining-reference-part measuring unit measures the position of the machining reference part of the workpiece, and machining-reference-part-measurement executing unit executes a position measuring operation for the machining reference part of the workpiece using the machining-reference-part measuring unit.