Wire EDM Temperature Control System for Dimensional Accuracy
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Solution Overview
Problem
In wire electric discharge machines, the machining liquid temperature control during inactive periods is inefficient, leading to dimensional errors in machined workpieces due to temperature variations, as existing methods struggle to accurately predict and adjust the temperature back to the control temperature before reactivation, wasting energy and delaying the start of machining.
Innovation Solution
A wire electric discharge machine with a temperature control system that calculates the required time to reach the machining liquid control temperature after inactivation, automatically enabling a timer function and activating a temperature regulator and pump to precisely control the machining liquid temperature, using a combination of sensors and tables to optimize the reactivation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the wire electric discharge machine is inactivated for a predetermined time, then power consumption is reduced, but the machining liquid temperature deviates from the control temperature causing dimensional errors
Solution Approach 1:
The system calculates the temperature regulation time required to restore the machining liquid temperature to the control temperature after inactivation, and automatically enables a timer function to start preparation for reactivation before the operator begins operation. This preliminary action ensures temperature recovery without requiring continuous power consumption during inactivation.
2Stability of the object's composition
If the machining liquid temperature is continuously controlled during inactive state, then temperature stability is maintained, but unnecessary energy is wasted
Solution Approach 1:
The system uses a temperature regulator and pump that can automatically restore the machining liquid temperature to the control temperature after inactivation. The controller calculates the required regulation time and activates these components only when needed, allowing the system to self-correct temperature deviations without continuous energy consumption.
3Productivity
If the machine is reactivated immediately after inactivation, then productivity is improved, but machining accuracy deteriorates due to temperature variations
Solution Approach 1:
The system includes a temperature sensor that continuously monitors the machining liquid temperature and provides feedback to the controller. Based on this feedback and the calculated temperature regulation time, the controller automatically manages the timer function and temperature regulator to ensure the temperature reaches the control temperature before machining begins, preventing dimensional errors while maintaining efficient reactivation.
4Measurement precision
If the timer function is manually set to start temperature regulation, then control precision is improved, but operation complexity increases
Solution Approach 1:
The controller automatically calculates the temperature regulation time based on the difference between the current temperature and control temperature, then automatically enables the timer function at the appropriate time before operation begins. This self-service approach eliminates the need for manual timer setting while maintaining precise temperature control.
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 solution ensures the machining liquid reaches the control temperature exactly when operation begins, minimizing power consumption and preventing dimensional errors, allowing for immediate and accurate machining without unnecessary energy waste.
Implementation Method 1
a temperature regulator for regulating the temperature of the machining liquid to a control temperature
Implementation Method 2
a machining liquid cooler which cools the machining liquid
Implementation Method 3
a pump for circulating the machining liquid between the machining liquid tank and the machining vessel
Implementation Method 4
generating electric discharge by applying a voltage across a machining gap between a wire electrode and the workpiece
Data Source
AI summary
A wire electric discharge machine has a function for controlling the machining liquid temperature. When it is predicted that the machining liquid temperature rises linearly, the machining liquid begins to be warmed at time t5b to reach machining liquid control temperature T2 at human operation beginning time t2. If the temperature rise at predetermined later time t8 is greater than predicted, temperature rising suspended from time t8 to a later time t9. Temperature rising resumed at time t9. This allows the machining liquid temperature to reach the machining liquid control temperature T2 without wasting electric power.