Wire Tip Position Detection for Hybrid Additive Machine Tools
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Solution Overview
Problem
Current machine tools face challenges in accurately identifying and correcting the position of the tip end of a wire during additive machining, which affects the precision and accuracy of the molten material deposition and subsequent cutting processes.
Innovation Solution
A machine tool configuration that includes a conduction block on the table to detect the position of the wire tip end, allowing for the switching of an electric circuit from an open to a closed state when contact is made, enabling precise position identification and correction of the wire tip end's position relative to its imaginary center axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire tip end position is not accurately detected, then the additive machining process is simpler, but the manufacturing precision of molten material deposition deteriorates
Solution Approach 1:
A conduction block is introduced as an intermediary detection element on the table surface. The wire tip end contacts this conduction block to establish electrical connection, enabling position detection without complex sensors. The conduction block serves as a simple yet effective mediator between the wire and the detection system.
Solution Approach 2:
The patent replaces complex mechanical position detection systems with an electrical detection method. By using electrical conductivity and circuit state changes (open to closed) to detect wire tip end position, the system achieves high precision without mechanical complexity.
2Manufacturing precision
If the wire tip end position is not corrected, then the control system is simpler, but the manufacturing precision of additive machining deteriorates
Solution Approach 1:
The system implements feedback control by detecting the wire tip end position through conduction block contact, calculating position displacement amounts, and correcting the estimated relative position of the machining head. This closed-loop feedback ensures high shape accuracy of added material.
Solution Approach 2:
The system performs preliminary position correction by calculating displacement amounts before actual additive machining begins. The estimated relative position of the machining head is corrected in advance based on detected wire tip end position, ensuring accuracy from the start of deposition.
3Reliability
If the wire tip end position detection is inaccurate, then the detection system is simpler, but the reliability of subsequent cutting process deteriorates
Solution Approach 1:
The conduction block detection system serves multiple functions: it detects wire tip end position for both additive machining accuracy and subsequent cutting accuracy. The same detection mechanism supports both machining processes, achieving high reliability without proportionally increasing system complexity.
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 of molten material deposition and subsequent cutting by ensuring precise positioning of the wire tip end, improving the shape and position accuracy of the added material and preventing excessive or insufficient cutting.
Implementation Method 1
a conduction block disposed on the table to detect a position of the tip end of the wire; a first electric circuit configured to be changed from an open state to a closed state by bringing the tip end of the wire into contact with the conduction block
Implementation Method 2
a first machining head which is configured to support a wire such that a tip end of the wire is exposed from the first machining head and via which a molten material produced from the tip end of the wire is provided to the workpiece supported by the table; a power supply configured to supply a current to the wire
Data Source
AI summary
A machine tool includes a first machining head which is configured to support a wire such that a tip end of the wire is exposed from the first machining head and via which a molten material produced from the tip end is provided to the workpiece supported by a table, a second machining head configured to support a tool to cut the workpiece, a power supply configured to supply a current to the wire, a conduction block disposed on the table to detect a position of the tip end, a drive device configured to relatively move the first machining head with respect to the table to bring the tip end of the wire into contact with the conduction block, and a first electric circuit configured to be changed from an open state to a closed state by bringing the tip end into contact with the conduction block.