Wire EDM Automatic Wire-Connection Pipe Stopper Mechanism
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Solution Overview
Problem
In wire electric discharge machining, the distal end of the electrode wire often becomes severely bent during breakage repairing, leading to derailing and failure in automatic connection due to a long distance between the AWF pipe nozzle and the pickup unit, resulting in incomplete cutting and machine stoppage.
Innovation Solution
A derailing prevention device with an automatic wire-connection pipe and a stopper mechanism that moves to reduce the distance between the AWF pipe nozzle and the pickup unit, ensuring the bent electrode wire can be properly clamped and cut, comprising a pipe stop arm driven by an air cylinder or servomotor, and a wedge-shaped member for secure clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the distance between the AWF pipe nozzle and the pickup unit is long, then the wire can be delivered further, but the bent distal end of the wire derails from the pickup unit and cannot be clamped
Solution Approach 1:
The pickup unit is made movable along the wire delivery direction rather than being fixed. This allows the pickup unit to dynamically adjust its position to accommodate the bent distal end of the wire, ensuring reliable clamping even when the wire is severely bent during breakage repairing operations
Solution Approach 2:
A guide structure is introduced as an intermediary component between the AWF pipe nozzle and the pickup unit. This guide structure constrains and directs the path of the wire, preventing the bent distal end from derailing and ensuring it reaches the pickup unit for successful clamping
2Shape
If the distal end of the wire is severely bent during breakage repairing, then the wire can be repositioned, but it derails from the pickup unit and cutting fails
Solution Approach 1:
The pickup unit is made movable to dynamically track and accommodate the position of the bent wire distal end, ensuring that even severely bent wires can be successfully clamped and cut without derailing
Solution Approach 2:
A detection unit is introduced to detect whether the wire has been successfully clamped by the pickup unit. This feedback mechanism allows the system to verify clamping success and prevent cutting failures, ensuring reliable operation even when the wire is severely bent
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
The solution significantly improves the success rate of automatic connection of bent electrode wires during breakage repairing by minimizing derailing and ensuring reliable clamping and cutting, thereby preventing machine stoppages and enhancing machining efficiency.
Implementation Method 1
the brake roller 6 is rotated in a wire delivery direction (indicated by arrow 101 in FIG. 6) to deliver the electrode wire 1 to a detection-unit electrode 5, in order to straighten the electrode wire 1 taken up by an AWF (auto wire feeder) pipe 4 by annealing
Implementation Method 2
cut the damaged distal end of the wire by energizing the electrode 5 and a chuck-section cutting electrode 7
Data Source
AI summary
A wire electric discharge machine is provided with an automatic wire-connection pipe movable between an automatic wire connection position and a retracted position. A pickup unit configured to clamp a wire electrode to be cut is disposed below a wire cutting electrode on the outlet side of the automatic wire-connection pipe. The wire electric discharge machine is further provided with a stopper mechanism configured to regulate a movement of the automatic wire-connection pipe so that a distal end of a nozzle of the automatic wire-connection pipe is located between the wire cutting electrode and the pickup unit when the wire electrode is cut.