Wire Electrode Threading via Compressed Air Micro-Vibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire electric discharge machining apparatuses face challenges in accurately threading a wire electrode through a start hole due to the small gap between the wire electrode and the start hole, leading to frequent failures and increased operation time.
Innovation Solution
The apparatus employs a vertical drive device that uses compressed air to vertically move the wire electrode slightly, allowing it to move freely and maintain straightness, with a feed roller and guide pipes to assist in guiding the wire electrode through the start hole, and a system to detect and manage wire tension and buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire electrode is fed towards the start hole with a small clearance, then the threading accuracy is improved, but the wire electrode may be caught by the inner wall or fail to reach the start hole
Solution Approach 1:
The patent applies horizontal micro-vibration to the wire electrode using a vibration generator. This vibration enables the wire to oscillate horizontally as it is fed towards the start hole, allowing it to navigate the small clearance without being caught by the inner wall and successfully thread through the start hole.
2Manufacturing precision
If the wire electrode is fed slowly to ensure precision, then the threading accuracy is improved, but the operation time is extended
Solution Approach 1:
The horizontal micro-vibration enables the wire electrode to move more efficiently through the start hole by oscillating horizontally, which reduces the time required for threading while maintaining accuracy. The vibration helps the wire navigate the clearance faster without sacrificing precision.
3Reliability
If the wire electrode is tightened after loosening, then the threading process can continue, but the operation time is significantly extended
Solution Approach 1:
The horizontal micro-vibration prevents the wire electrode from loosening during the feeding process by maintaining steady contact and alignment with the start hole. This eliminates the need to stop and retighten the wire, thereby preventing repetitive failures and significantly reducing the total operation time.
4Device complexity
If the upper wire guide is positioned away from the start hole, then the device structure is simplified, but the threading probability is reduced
Solution Approach 1:
The horizontal micro-vibration compensates for the increased distance between the upper wire guide and the start hole by enabling the wire to oscillate and navigate the gap more effectively. This maintains a high threading probability even when the wire guide is positioned away from the start hole, allowing for simplified device structure.
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 enhances the accuracy and speed of wire threading by minimizing mechanical constraints on the wire electrode's movement, enabling it to be threaded through the start hole efficiently with reduced likelihood of failure and shorter operation times.
Implementation Method 1
a vertical drive device (30) which is disposed between the feed roller and the start hole and supplies compressed air in the upward direction and in the downward direction to vertically move the wire electrode slightly
Data Source
Figure 1
Figure 2
Figure 3A~3F
AI summary
In order to provide a wire electric discharge machining apparatus equipped with an automatic wire threader more reliably threading a wire electrode through an start hole, a wire electric discharge machining apparatus includes an automatic wire threader (1) including: a feed roller (10) disposed higher than the start hole (4) and feeding a wire electrode (2) toward the start hole; and a vertical drive device (30) disposed between the feed roller and the start hole, and supplying compressed air in the upward and downward directions to vertically move the wire electrode slightly . The vertical drive device includes wire guides (32, 82) having guide holes through which the wire electrode is passed. The wire guides (32, 82) are constructed so that upward movement by the compressed air is possible.