Wire Electrode Tension Control for Short Circuit Termination
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Solution Overview
Problem
Wire electric discharge machining devices face challenges in reliably terminating unintentional short circuits between the wire electrode and workpiece, especially when the start hole is not formed vertically, leading to contact with the top or bottom face of the workpiece.
Innovation Solution
A wire electric discharge machining device equipped with a tension control device, short circuit detector, and short circuit termination system that reduces wire electrode tension and vibrates the electrode using high-pressure dielectric liquid or compressed air to effectively terminate short circuits by bending the wire electrode within the start hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire electrode is moved within the xy plane to terminate a short circuit, then the short circuit between the wire electrode and the workpiece can be terminated, but the wire electrode may still contact the top or bottom face of the workpiece when the start hole is not vertical
Solution Approach 1:
The invention introduces vertical movement of the wire electrode along the z-axis (perpendicular to the xy plane) in addition to the conventional horizontal movement within the xy plane. This dimensional extension allows the wire electrode to escape contact with both top and bottom faces of the workpiece by moving out of the problematic plane, thereby reliably terminating short circuits even when the start hole is not vertical.
2Stability of the object's composition
If the wire electrode is given high tension to maintain stability during machining, then the wire electrode remains stable and straight, but the wire electrode cannot be bent effectively to terminate short circuits
Solution Approach 1:
The invention dynamically adjusts the tension of the wire electrode based on operational requirements. During normal machining, high tension is applied to maintain wire stability and straightness. When a short circuit is detected, the tension is temporarily reduced to allow the wire to be bent or vibrated for terminating the short circuit, then restored to high tension to resume stable machining. This dynamic tension control resolves the contradiction between stability and short circuit termination capability.
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 reliably terminates short circuits even if the start hole is not vertical, preventing burrs and ensuring consistent machining by reducing tension and vibrating the wire electrode to create a machining gap.
Implementation Method 1
a tension control device (56) that controls tension of the wire electrode so as to maintain the tension at a set value
Implementation Method 2
a short circuit detector (57) that detects a short circuit between the wire electrode and the workpiece
Implementation Method 3
The short circuit termination system may include a vibration device that vibrates the wire electrode by jetting a high pressure dielectric liquid to the wire electrode
Implementation Method 4
The vertical motion device (30) may supply the compressed air in a manner to cross the wire electrode to vibrate the wire electrode transversely
Implementation Method 5
a wire electric discharge machining device that starts machining of a workpiece (3) by generating an electric discharge in a machining gap formed between the workpiece and a wire electrode (2)
Data Source
AI summary
Provided is a wire electric discharge machining device and method capable of reliably terminating a short circuit between a wire electrode and a workpiece. The invention relates to a wire electric discharge machining device that starts machining of a workpiece (3) by generating an electric discharge in a machining gap formed between the workpiece and a wire electrode (2) threaded through a start hole (4) in the workpiece. The wire electric discharge machining device includes: a tension control device (56) that controls tension of the wire electrode so as to maintain the tension at a set value; a short circuit detector (57) that detects a short circuit between the wire electrode and the workpiece; and a short circuit termination system that reduces the tension of the wire electrode and vibrates the wire electrode in order to terminate a short circuit when the short circuit detector has detected the short circuit.