Wire Electrode Supply Apparatus for Stable Tension Control
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Solution Overview
Problem
Conventional wire electrical discharge machining devices face challenges in stabilizing the tension of fine wire electrodes with diameters of 0.1 mm or less, leading to vibration issues that affect surface roughness and machining precision.
Innovation Solution
A wire electrode supply apparatus with a dual-tension system, comprising a high-tension and low-tension applying unit, and a constant pressure ejecting mechanism, which adjusts and applies tension in a controlled manner to reduce vibration, using a hysteresis brake and powder brake respectively, and a dancer roller for back tension adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single tension applying unit is used, then the device complexity is low, but the manufacturing precision deteriorates due to inability to provide stable tension for fine wire electrodes
Solution Approach 1:
The tension applying unit is divided into two independent units: a first tension applying unit and a second tension applying unit. Each unit can independently apply tension to the wire electrode, allowing for more precise and stable tension control. This segmentation enables the system to handle fine wire electrodes (0.1mm or less) with the required stability while maintaining the capability for wider tension adjustment ranges.
2Stability of the object's composition
If high tension is applied to stabilize the wire electrode, then the wire vibration is reduced, but the surface roughness deteriorates due to excessive tension on fine wires
Solution Approach 1:
Different tension levels are applied at different locations in the wire path. The first tension applying unit applies a first level of tension, while the second tension applying unit applies a different level of tension. This local differentiation allows the wire to be stabilized in the transport path without subjecting it to excessive tension during the machining process, thereby preventing surface roughness deterioration.
Solution Approach 2:
The tension applying system is made dynamic and adjustable. The tension applying units can independently adjust their tension levels based on the specific requirements of the wire electrode diameter and material. This dynamic adjustment capability allows optimization of wire stability for each machining condition without causing excessive tension that would harm surface quality.
3Manufacturing precision
If the wire electrode diameter is reduced to 0.1mm or less for microstructure machining, then the machining precision is improved, but the wire tension stability deteriorates
Solution Approach 1:
The tension control system is segmented into multiple independent units that can provide staged tension application. This segmentation allows for fine-tuned tension control suitable for ultra-fine wire electrodes of 0.1mm or less diameter, providing the necessary stability without requiring excessive tension that would compromise the wire or surface quality.
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 apparatus significantly reduces wire vibration by up to ⅓, improves tension control, and prevents twisting and loosening, enabling precise machining of microstructures and narrow slit portions with improved surface roughness.
Implementation Method 1
A brake roller 171 is pressed in contact with the brake pulley 169 such that the wire electrode is pinched between the brake roller 171 and the brake pulley 169, thereby further applying tension to the wire electrode. The brake roller 171 employs a brake motor (hysteresis motor).
Implementation Method 2
a low tension applying unit that applies a low tension to the wire electrode; and a constant pressure ejecting unit that ejects the wire electrode in a state in which the wire electrode is pinched with a constant pressure
Data Source
AI summary
The present invention provides a wire electrode supply apparatus for suppressing wire electrode driving vibration for wire electrodes having a wide range of diameters and formed of various materials, thereby improving processed surface roughness. The wire electrode supply apparatus includes a back tension adjustment unit that adjusts a back tension of the wire electrode drawn from a source bobbin, a tension applying unit, and a constant pressure ejecting unit that ejects the wire electrode with constant pressure and rate after the transference via the tension applying unit and an electrical discharge machining unit. The tension applying unit includes a low tension applying unit that applies a tension to the wire electrode, and a high tension applying unit that can supply a higher tension. After the high tension applying unit supplies a tension, the low tension applying unit supplies a tension. Otherwise, only the low tension applying unit supplies a tension.