Wire EDM Surface Position Sensing for Tapered Machining Accuracy
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Solution Overview
Problem
Existing wire electrical discharge machines struggle to accurately determine the vertical positions of top and bottom surfaces of workpieces with different shapes, leading to machining inaccuracies.
Innovation Solution
A wire electrical discharge machining system and control method that utilize a distance measuring sensor and numerical controller to calculate the vertical positions of the top and bottom surfaces by measuring distances from a reference surface, enabling precise determination and input of these positions into the machining system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual measurement methods are used to determine vertical positions, then measurement can be performed, but operator workload increases and machining accuracy decreases
Solution Approach 1:
The measurement system performs self-measurement by automatically using the distance measuring sensor to measure distances to both the top and bottom surfaces of the workpiece. The numerical controller automatically calculates the vertical positions based on these measurements, eliminating the need for manual measurement operations by operators. This self-service approach reduces operator workload while maintaining high machining accuracy through automated precise measurement and calculation.
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 allows for accurate setting of the vertical positions of the top and bottom surfaces, enhancing machining accuracy and reducing operator workload by automating the measurement process.
Implementation Method 1
a distance measuring sensor 72 attached to the wire electrical discharge machine 10 measures a vertical distance from the distance measuring sensor 72 to the top surface Wa of the workpiece W
Data Source
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AI summary
A wire electrical discharge machine (10) machines a workpiece (W) so as to have different machined shapes on a top surface (Wa) and a bottom surface (Wb) of the workpiece (W). The wire electrical discharge machine (10) includes: a distance measuring sensor (72) for moving within a machining area (74) of the wire electrical discharge machine (10) and measuring a distance between the distance measuring sensor (72) and an object to be measured; and a vertical position calculating unit (84) for calculating a distance between a reference surface (S) and the top surface (Wa) and a distance between the reference surface (S) and the bottom surface (Wb), from a distance between the reference surface (S) and the distance measuring sensor (72), a distance between the top surface (Wa) and the distance measuring sensor (72), and a distance between the bottom surface (Wb) and the distance measuring sensor (72), measured by the distance measuring sensor (72).