Wire Electrical Discharge Machine Tension Detection
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Solution Overview
Problem
Conventional wire electrical discharge machines fail to detect the position of a wire electrode on the wire feed path and its feed state accurately, especially when the wire electrode strays away from the original path or is not stuck on an object, leading to incomplete machining.
Innovation Solution
A wire electrical discharge machine equipped with a supply roller, collection roller, guide parts, fluid paths for compressed fluid supply, a tension detector, and a control device that determines the wire electrode's position by monitoring tension changes and controlling the fluid supply, allowing accurate detection of the wire electrode's position and feed state through sequential fluid path activation and pressure variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If only flexure detection is used to detect wire electrode getting stuck, then the detection method is simple, but it is impossible to detect how far the wire electrode has proceeded on the wire feed path
Solution Approach 1:
The wire feed path is divided into multiple sections with fluid paths supplied at different positions. By detecting tension changes in each section sequentially, the system can determine the wire electrode's position along the feed path without requiring a single complex detection system.
Solution Approach 2:
A tension detector is introduced as an intermediary device to indirectly measure the wire electrode's position. Instead of directly tracking the wire's location, the system uses tension changes caused by compressed fluid supply to infer position, simplifying the overall detection mechanism.
2Measurement precision
If compressed fluid is supplied to feed the wire electrode along the wire feed path, then the wire electrode can be conveyed accurately, but it is difficult to determine whether the wire electrode has reached the supply position
Solution Approach 1:
The tension detector provides real-time feedback on wire electrode tension as compressed fluid is supplied. When the wire reaches the fluid supply position, a characteristic tension change occurs, allowing the control device to automatically determine arrival at the supply position through this feedback signal.
Solution Approach 2:
The system monitors changes in wire electrode tension as a parameter to detect position. By observing how tension varies when compressed fluid is supplied versus when it is not, the system can determine whether the wire has reached the supply position without direct visual or physical contact detection.
3Measurement precision
If multiple fluid paths are supplied at different positions along the wire feed path, then the position detection accuracy is improved, but the device complexity increases
Solution Approach 1:
The compressed fluid supply system serves multiple functions: it both feeds the wire electrode along the feed path and enables position detection. The same fluid paths that convey the wire also create the tension changes used for detection, eliminating the need for separate detection infrastructure.
Solution Approach 2:
The wire electrode itself serves as the detection medium. As the wire is fed through the compressed fluid supply positions, its own tension changes provide the detection signal. The system uses the wire's physical response to the fluid supply rather than requiring external sensors at each position.
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 detection of the wire electrode's position and feed state, preventing errors due to noise in tension detection and ensuring efficient machining by determining the correct position of the wire electrode on the feed path.
Implementation Method 1
a tension detector configured to detect the tension of the wire electrode
Implementation Method 2
a fluid path formed with the guide part to supply a compressed fluid to the wire feed path so as to feed the wire electrode along the wire feed path
Data Source
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AI summary
A wire electrical discharge machine (10) having an auto wire feeding function includes: guide parts arranged on a wire feed path along which the wire electrode (12) is fed so as to guide the feeding of the wire electrode (12); fluid paths (FP) formed with the guide parts to supply a compressed fluid to the wire feed path; a compressed fluid supply device (16) to supply the compressed fluid to the fluid paths (FP); a tension detector (34) to detect the tension of the wire electrode (12); and a control device (18) that controls the compressed fluid supply device (16) so as to supply the compressed fluid to the fluid paths (FP), and based on the detection result from the tension detector (34), determines whether or not the wire electrode (12) has reached a supply position (SP) of one of the fluid paths (FP) on the wire feed path to which the fluid has been supplied.