Wire EDM Controller Correcting Machining Routes via Extension and Removal Distances
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Solution Overview
Problem
Existing wire electric discharge machining technologies face challenges in accurately correcting machining routes due to wire electrode deflection, especially in complex shapes and varying machining environments, as they rely on pre-defined parameters that do not account for disturbances and environmental influences, leading to inconsistent machining results.
Innovation Solution
A wire electric discharge machine controller that uses machining program commands to correct the machining route by specifying extension and removal distances for each machining block, allowing for precise reflection of the operator's intentions and adaptation to different machining conditions through a machining program storage unit, analyzing unit, correcting unit, and controlling unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-defined parameters are used to correct machining routes, then the correction process is simplified, but the accuracy and adaptability to varying machining environments deteriorates
Solution Approach 1:
The system dynamically adjusts correction amounts based on real-time machining conditions rather than using fixed pre-defined parameters. The correction amount calculation unit computes specific correction values for each machining block by considering the actual machining environment, wire electrode deflection characteristics, and geometric features, enabling adaptive correction that maintains high accuracy across varying conditions.
Solution Approach 2:
The system changes the correction parameters dynamically based on machining conditions. Instead of using constant pre-defined parameters, the correction amount varies according to the specific machining block, wire electrode state, and environmental factors. This parameter adaptation allows the system to maintain manufacturing precision while keeping the operation relatively simple through automated calculation.
2Device complexity
If pre-defined parameters are used for machining route correction, then the system complexity is reduced, but the adaptability to different machining conditions deteriorates
Solution Approach 1:
The system performs self-correction by automatically calculating appropriate correction amounts based on its own sensing of machining conditions. The correction amount calculation unit uses information from the machining state to compute and apply corrections without requiring complex external parameter setting or manual intervention for each machining condition, achieving adaptability while maintaining manageable system complexity.
Solution Approach 2:
The system incorporates feedback mechanisms where the actual machining conditions are continuously monitored and fed back to the correction amount calculation unit. This feedback loop enables the system to adapt to different machining conditions by adjusting correction amounts based on real-time information about wire electrode deflection, machining speed, and geometric features, enhancing versatility without proportionally increasing system complexity.
3Manufacturing precision
If machining speed and energy are controlled to secure shape accuracy at corners, then the shape accuracy is improved, but the machining time increases
Solution Approach 1:
The system performs preliminary correction by pre-calculating and applying route corrections before machining each block. The correction amount calculation unit determines the necessary correction in advance based on the machining program and predicted deflection characteristics, allowing the wire electrode to follow the corrected route without requiring speed reduction or energy control at corners, thus maintaining both accuracy and productivity.
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 precise correction of machining routes according to operator intentions, improving accuracy and adaptability to various machining conditions, even in complex shapes and environments, by connecting extension points and new start points based on specified distances, thus enhancing machining precision and consistency.
Implementation Method 1
wire electric discharge machining
Implementation Method 2
discharge repulsion force arising between the wire electrode and the workpiece
Implementation Method 3
flow of machining liquid
Data Source
AI summary
A block in an electric discharge machining program is read out and analyzed, and when determined that a machining route correction command is issued to correct the machining route at a corner formed by consecutive first and second machining blocks, the machining route is corrected such that the end point of the first machining block, an extension point obtained by extending the first machining block from the end point thereof by a predetermined distance in the machining advancing direction, and a new start point obtained by partially removing the second machining block by a predetermined distance from the start point thereof are connected. Then, the wire electrode is moved with respect to the workpiece, following the corrected machining route.