Patent Application
20240269757
The present invention relates to a wire electrical discharge machine for performing machining of a workpiece by generating an electric discharge between a wire electrode and the workpiece, as well as to a control method for such a wire electrical discharge machine.
In WO 2015/145484 A1, a wire electrical discharge machine is disclosed. The wire electrical discharge machine includes a control unit that controls a machining speed (a relative speed of a machining electrode with respect to a workpiece). A difference between the machining speed and a setting speed is correlated with a distance (a side gap) between the machining electrode and the workpiece. For this reason, in accordance with the difference between the machining speed and the setting speed, the control unit compensates an average inter-electrode machining voltage between the machining electrode and the workpiece. The control unit controls the machining speed based on the compensated average inter-electrode machining voltage. Consequently, the wire electrical discharge machine can maintain a constant side gap during electrical discharge machining, and is capable of improving the machining accuracy of the workpiece.
The correlation between a size of the difference between the machining speed and the setting speed, and a size of the side gap becomes smaller as the difference between the machining speed and the setting speed becomes larger. Therefore, in the wire electrical discharge machine according to WO 2015/145484 A1, a problem arises in that the machining accuracy of the workpiece decreases as the difference between the machining speed and the setting speed increases.
The present invention has the object of solving the problem described above.
A first aspect of the present invention is characterized by a wire electrical discharge machine configured to carry out machining of a workpiece by generating an electric discharge in an inter-electrode gap between a wire electrode and the workpiece, the wire electrical discharge machine including a discharge state value acquisition unit configured to acquire, as a discharge state value, any one of an average inter-electrode voltage, which is a time average of a voltage applied to the inter-electrode gap, a reciprocal of a number of discharge pulses in the inter-electrode gap per unit time, or a discharge delay time period, which is a time period from when the voltage is applied to the inter-electrode gap until when electric discharging takes place in the inter-electrode gap, a discharge state value compensation unit configured to compensate the discharge state value to obtain a compensated value in accordance with a machining speed, which is a relative speed of the wire electrode with respect to the workpiece, a driving unit configured to cause the wire electrode to move relatively with respect to the workpiece, and a control unit configured to control the driving unit based on the compensated value, and thereby keep a size of the inter-electrode gap constant during machining, wherein the discharge state value compensation unit determines the compensated value based on an equation in which the discharge state value defines a numerator, and a value obtained by exponentiation with a coefficient as a base and the machining speed as an exponent defines a denominator.
A second aspect of the present invention is characterized by a method of controlling a wire electrical discharge machine configured to carry out machining of a workpiece by generating an electric discharge in an inter-electrode gap between a wire electrode and the workpiece, the method of controlling the wire electrical discharge machine including a discharge state value acquisition step of acquiring, as a discharge state value, any one of an average inter-electrode voltage, which is a time average of a voltage applied to the inter-electrode gap, a reciprocal of a number of discharge pulses in the inter-electrode gap per unit time, or a discharge delay time period, which is a time period from when the voltage is applied to the inter-electrode gap until when electric discharging takes place in the inter-electrode gap, a discharge state value compensation step of compensating the discharge state value to obtain a compensated value in accordance with a machining speed, which is a relative speed of the wire electrode with respect to the workpiece, a driving step of causing the wire electrode to move relatively with respect to the workpiece by a driving unit, and a control step of controlling the driving unit based on the compensated value, and thereby keeping a size of the inter-electrode gap constant during machining, wherein, in the discharge state value compensation step, the compensated value is determined based on an equation in which the discharge state value defines a numerator, and a value obtained by exponentiation with a coefficient as a base and the machining speed as an exponent defines a denominator.
According to the present invention, the wire electrical discharge machine is capable of improving the machining accuracy of the workpiece.
The machine main body 16 includes a machining electrical power source 20, an inter-electrode voltage detection unit 22, an X-axis motor 24, and a Y-axis motor 26. The machining electrical power source 20 applies a voltage to the inter-electrode gap between the electrode and the workpiece. The inter-electrode voltage detection unit 22 is a voltage sensor that detects a voltage applied to the inter-electrode gap between the electrode and the workpiece (hereinafter also referred to simply as an inter-electrode voltage). The X-axis motor 24 and the Y-axis motor 26 cause a non-illustrated work table to move. By the workpiece 14, which is fixed to the work table, moving together with the work table, the wire electrode 12 undergoes relative movement with respect to the workpiece 14.
The control device 18 includes a computation unit 28 and a storage unit 30. The computation unit 28 is constituted by a processor, for example, such as a CPU (Central Processing Unit), a GPU (Graphics Processing Unit), or the like. The computation unit 28 includes an average inter-electrode voltage calculation unit 32, a compensation unit 34, a motor control unit 36, and a machining electrical power source control unit 38. The average inter-electrode voltage calculation unit 32, the compensation unit 34, the motor control unit 36, and the machining electrical power source control unit 38 are realized by a program stored in the storage unit 30 being executed by the computation unit 28. At least one of the average inter-electrode voltage calculation unit 32, the compensation unit 34, the motor control unit 36, or the machining electrical power source control unit 38 may be realized by an integrated circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field-Programmable Gate Array) or the like. At least one of the average inter-electrode voltage calculation unit 32, the compensation unit 34, the motor control unit 36, or the machining electrical power source control unit 38 may be constituted by an electronic circuit including a discrete device.
The storage unit 30 is constituted by a non-illustrated volatile memory, and a non-illustrated non-volatile memory. The volatile memory is, for example, by a RAM (Random Access Memory). For example, data that is used temporarily is stored in the volatile memory. The non-volatile memory, for example, is a ROM (Read Only Memory), a flash memory, or the like. For example, programs, tables, maps, and the like are stored in the non-volatile memory. At least a portion of the storage unit 30 may be provided in the aforementioned processor, the integrated circuit, or the like.
The average inter-electrode voltage calculation unit 32 calculates a time average of the inter-electrode voltage detected by the inter-electrode voltage detection unit 22. Hereinafter, the time average of the inter-electrode voltage may be referred to as an average inter-electrode voltage. The average inter-electrode voltage calculation unit 32 corresponds to the discharge state value acquisition unit of the present invention. The compensation unit 34 compensates the average inter-electrode voltage in accordance with the relative speed of the wire electrode 12 with respect to the workpiece 14. Hereinafter, the relative speed of the wire electrode 12 with respect to the workpiece 14 may be referred to as a machining speed. The compensation of the average inter-electrode voltage performed in the compensation unit 34 will be described in detail later. The compensation unit 34 corresponds to the discharge state value compensation unit of the present invention. The motor control unit 36 controls the X-axis motor 24 and the Y-axis motor 26, and thereby sets the machining speed to a target machining speed. The target machining speed is set based on the average inter-electrode voltage obtained after compensation thereof has been carried out in the compensation unit 34. Hereinafter, the average inter-electrode voltage on which compensation thereof has been performed in the compensation unit 34 may be referred to as a compensated average inter-electrode voltage. The motor control unit 36 corresponds to the control unit of the present invention. The machining electrical power source control unit 38 controls the machining electrical power source 20, and thereby applies a voltage to the inter-electrode gap.
Moreover, it should be noted that the motor control unit 36 may perform a proportional control, an integral control, and a derivative control (PID control) on the X-axis motor 24 and the Y-axis motor 26. The motor control unit 36 may control the X-axis motor 24 and the Y-axis motor 26 based on the target machining speed, which is set based on the average inter-electrode voltage prior to being compensated. In this case, the motor control unit 36 may set at least one of a proportional gain, an integration time, or a derivative time in accordance with the compensated average inter-electrode voltage.
During electrical discharge machining of the workpiece 14, it is difficult to directly detect the electric discharge gap by the wire electrical discharge machine 10. Thus, according to the present embodiment, instead of controlling the X-axis motor 24 and the Y-axis motor 26 on the basis of the electric discharge gap, the motor control unit 36 controls the X-axis motor 24 and the Y-axis motor 26 based on the average inter-electrode voltage.
However, even if the average inter-electrode voltage during electrical discharge machining of the workpiece 14 is constant, the electric discharge gap becomes smaller as the machining speed increases. Thus, according to the present embodiment, the compensation unit 34 compensates the average inter-electrode voltage on the basis of the machining speed, and thereby obtains a compensated average inter-electrode voltage. The motor control unit 36 controls the X-axis motor 24 and the Y-axis motor 26 based on the compensated average inter-electrode voltage. Consequently, the electric discharge gap during electrical discharge machining of the workpiece 14 is kept substantially constant.
The compensated average inter-electrode voltage is determined by the following Equation (1). “Ec” in the equation indicates the compensated average inter-electrode voltage. “E” in the equation indicates the average inter-electrode voltage. “α1” in the equation indicates a coefficient. “V” in the equation indicates the machining speed.
In the wire electrical discharge machine 10 according to the present embodiment, the compensation unit 34 determines the compensated average inter-electrode voltage on the basis of an equation in which the average inter-electrode voltage defines a numerator, and a value obtained by exponentiation with the coefficient as the base and the machining speed as the exponent defines a denominator. The motor control unit 36 controls the X-axis motor 24 and the Y-axis motor 26 based on the compensated average inter-electrode voltage, and thereby keeps the size of the electric discharge gap constant during machining. In accordance with this feature, the wire electrical discharge machine 10 is capable of improving the machining accuracy of the workpiece 14.
In the wire electrical discharge machine 10 according to the present embodiment, the compensation unit 34 determines the compensated average inter-electrode voltage on the basis of the above-described Equation (1). In accordance with this feature, regardless of the machining speed, the wire electrical discharge machine 10 is capable of keeping the size of the electric discharge gap constant during electrical discharge machining of the workpiece 14.
In the wire electrical discharge machine 10, the motor control unit 36, in accordance with the compensated average inter-electrode voltage, sets at least one of the proportional gain of the proportional control, the integration time of the integral control, the derivative time of the derivative control, or the target machining speed. In accordance with this feature, the wire electrical discharge machine 10 is capable of improving the machining accuracy of the workpiece 14.
In the first embodiment, the motor control unit 36 sets the target machining speed based on the average inter-electrode voltage. In contrast to this feature, according to the present embodiment, the target machining speed is set based on a reciprocal of the number of discharge pulses per unit time. In the example shown in
The discharge pulse number calculation unit 40 determines the number of discharge pulses per unit time based on the inter-electrode voltage detected by the inter-electrode voltage detection unit 22, and calculates the reciprocal of the number of discharge pulses. When a voltage is applied to the inter-electrodes gap and then the insulation between the electrode and the workpiece breaks down to cause an electric discharge, the inter-electrode voltage decreases. The discharge pulse number calculation unit 40 calculates the number of discharge pulses based on the number of times that a voltage is applied to the inter-electrode gap, and thereafter, the inter-electrode voltage becomes less than or equal to a predetermined voltage. The discharge pulse number calculation unit 40 corresponds to the discharge state value acquisition unit of the present invention. The compensation unit 42 compensates the reciprocal of the number of discharge pulses in accordance with the machining speed, and thereby determines the compensated reciprocal of the number of discharge pulses. A description will be given later concerning the compensation of the reciprocal of the number of discharge pulses performed in the compensation unit 42. The compensation unit 42 corresponds to the discharge state value compensation unit of the present invention. The motor control unit 44 controls the X-axis motor 24 and the Y-axis motor 26, and thereby sets the machining speed to a target machining speed. The target machining speed is set based on the reciprocal of the number of discharge pulses that has been compensated in the compensation unit 42. Hereinafter, the number of discharge pulses after having been compensated may be referred to as the number of compensated discharge pulses. The motor control unit 44 corresponds to the control unit of the present invention. The reciprocal of the number of compensated discharge pulses corresponds to the compensated value of the present invention.
Moreover, it should be noted that the motor control unit 44 may perform a proportional control, an integral control, or a derivative control (PID control) on the X-axis motor 24 and the Y-axis motor 26. The motor control unit 44 may control the X-axis motor 24 and the Y-axis motor 26 based on the target machining speed that has been set based on the reciprocal of the number of discharge pulses prior to being compensated. In this case, the motor control unit 44 may set at least one of the proportional gain, the integration time, or the derivative time in accordance with the reciprocal of the number of compensated discharge pulses.
The compensation unit 42 determines the reciprocal of the number of compensated discharge pulses on the basis of the following Equation (2). “Nc” in the equation indicates the reciprocal of the number of compensated discharge pulses. “N” in the equation indicates the reciprocal of the number of discharge pulses. “α2” in the equation indicates a coefficient. “V” in the equation indicates the machining speed.
As shown in
In the wire electrical discharge machine 10 according to the present embodiment, the compensation unit 42 determines the reciprocal of the number of compensated discharge pulses on the basis of an equation in which the reciprocal of the number of discharge pulses per unit time defines a numerator, and the value obtained by exponentiation with the coefficient as the base and the machining speed as the exponent defines a denominator. The motor control unit 44 controls the X-axis motor 24 and the Y-axis motor 26 based on the number of compensated discharge pulses, and thereby keeps the size of the electric discharge gap constant during machining. In accordance with this feature, the wire electrical discharge machine 10 is capable of improving the machining accuracy of the workpiece 14.
In the wire electrical discharge machine 10 according to the present embodiment, the compensation unit 42 determines the reciprocal of the number of compensated discharge pulses on the basis of the above-described Equation (2). In accordance with this feature, regardless of the machining speed, the wire electrical discharge machine 10 is capable of keeping the size of the electric discharge gap constant during electrical discharge machining of the workpiece 14.
In the wire electrical discharge machine 10 according to the present embodiment, the discharge pulse number calculation unit 40 determines the number of discharge pulses per unit time based on the inter-electrode voltage detected by the inter-electrode voltage detection unit 22, and calculates the reciprocal of the number of discharge pulses. The compensation unit 42 determines the reciprocal of the number of compensated discharge pulses on the basis of the above-described Equation (2). Since the number of discharge pulses per unit time does not change in accordance with the voltage applied to the inter-electrode gap (between the electrode and the workpiece), there is no need for the compensation unit 42 to change the coefficient “α2” of Equation (2) in accordance with the voltage applied to the inter-electrode gap, and the processing load in the compensation unit 42 can be reduced.
In the wire electrical discharge machine 10 according to the present embodiment, the motor control unit 44, in accordance with the reciprocal of the compensated number of discharge pulses, sets at least one of the proportional gain of the proportional control, the integration time of the integral control, the derivative time of the derivative control, or the target machining speed. In accordance with this feature, the wire electrical discharge machine 10 is capable of improving the machining accuracy of the workpiece 14.
In the first embodiment, the electric discharge gap is estimated based on the average inter-electrode voltage. In contrast to this feature, according to the present embodiment, the electric discharge gap is estimated on the basis of a discharge delay time period. As shown in
The discharge delay time period calculation unit 46 calculates the discharge delay time period based on the inter-electrode voltage detected by the inter-electrode voltage detection unit 22. When discharging takes place after the voltage is applied to the inter-electrode gap, the inter-electrode voltage decreases. The discharge delay time period calculation unit 46 calculates the discharge delay time period based on the time period from when the voltage is applied to the inter-electrode gap until the inter-electrode voltage becomes less than or equal to a predetermined voltage. The discharge delay time period calculation unit 46 corresponds to the discharge state value acquisition unit of the present invention. The compensation unit 48 compensates the discharge delay time period in accordance with the machining speed. A description will be given later concerning the compensation of the discharge delay time period performed in the compensation unit 48. The compensation unit 48 corresponds to the discharge state value compensation unit of the present invention. The motor control unit 50 controls the X-axis motor 24 and the Y-axis motor 26, and thereby sets the machining speed to a target machining speed. The target machining speed is set based on the discharge delay time period that has been compensated in the compensation unit 48. Hereinafter, the discharge delay time period that has been compensated by the compensation unit 48 may be referred to as a compensated discharge delay time period. The motor control unit 50 corresponds to the control unit of the present invention.
Moreover, it should be noted that the motor control unit 50 may perform a proportional control, an integral control, or a derivative control (PID control) on the X-axis motor 24 and the Y-axis motor 26. The motor control unit 50 may control the X-axis motor 24 and the Y-axis motor 26 based on the target machining speed, which is set based on the discharge delay time period prior to being compensated. In this case, the motor control unit 50 may set at least one of the proportional gain, the integration time, or the derivative time in accordance with the compensated discharge delay time period.
The compensation unit 48 determines the compensated discharge delay time period on the basis of the following Equation (3). “Tc” in the equation indicates the compensated discharge delay time period. “T” in the equation indicates the discharge delay time period. “α3” in the equation indicates a coefficient. “V” in the equation indicates the machining speed.
As shown in
In the wire electrical discharge machine 10 according to the present embodiment, the compensation unit 48 determines the compensated discharge delay time period on the basis of an equation in which the discharge delay time period defines a numerator, and a value obtained by exponentiation with the coefficient as the base and the machining speed as the exponent defines a denominator. The motor control unit 50 controls the X-axis motor 24 and the Y-axis motor 26 based on the compensated discharge delay time period, and thereby keeps the size of the electric discharge gap constant during electrical discharge machining of the workpiece 14. In accordance with this feature, the wire electrical discharge machine 10 is capable of improving the machining accuracy of the workpiece 14.
In the wire electrical discharge machine 10 according to the present embodiment, the compensation unit 48 determines the compensated discharge delay time period on the basis of the above-described Equation (3). In accordance with this feature, regardless of the machining speed, the wire electrical discharge machine 10 is capable of keeping the size of the electric discharge gap constant during machining.
In the wire electrical discharge machine 10 according to the present embodiment, the discharge delay time period calculation unit 46 calculates the discharge delay time period based on the inter-electrode voltage detected by the inter-electrode voltage detection unit 22. The compensation unit 48 determines the compensated discharge delay time period on the basis of the above-described Equation (3). Since the discharge delay time period does not change in accordance with the voltage applied to the inter-electrode gap, there is no need for the compensation unit 48 to change the coefficient “α3” of Equation (3) in accordance with the voltage applied to the inter-electrode gap, and the processing load in the compensation unit 48 can be reduced.
In the wire electrical discharge machine 10 according to the present invention, the motor control unit 50, in accordance with the compensated discharge delay time period, sets at least one of the proportional gain of the proportional control, the integration time of the integral control, the derivative time of the derivative control, or the target machining speed. In accordance with this feature, the wire electrical discharge machine 10 is capable of improving the machining accuracy of the workpiece 14.
It should be noted that the present invention is not limited to the above-described embodiments, and various configurations can be adopted therein without departing from the essence and gist of the present invention.
Technical concepts that are capable of being grasped from the above-described embodiments will be described below.
In the wire electrical discharge machine (10) that carries out machining of the workpiece (14) by generating an electric discharge in the inter-electrode gap between the wire electrode (12) and the workpiece, the wire electrical discharge machine includes the discharge state value acquisition unit (32) that acquires as the discharge state value any one of the average inter-electrode voltage, which is a time average of the voltage applied to the inter-electrode gap, the reciprocal of the number of discharge pulses in the inter-electrode gap per unit time, or the discharge delay time period, which is the time period from when the voltage is applied to the inter-electrode gap until when electric discharging takes place in the inter-electrode gap, the discharge state value compensation unit (34) that compensates the discharge state value to obtain the compensated value in accordance with the machining speed, which is the relative speed of the wire electrode with respect to the workpiece, the driving unit (24, 26) that causes the wire electrode to move relatively with respect to the workpiece, and the control unit (36) that controls the driving unit based on the compensated value, and thereby keeps the size of the inter-electrode gap constant during machining, wherein the discharge state value compensation unit determines the compensated value based on an equation in which the discharge state value defines a numerator, and the value obtained by exponentiation with the coefficient as the base and the machining speed as the exponent defines a denominator. In accordance with these features, the wire electrical discharge machine is capable of improving the machining accuracy of the workpiece.
In the above-described wire electrical discharge machine, the discharge state value compensation unit may determine the compensated value based on the equation Sc=S/α(1+V) where the compensated value is Sc, the discharge state value is S, the coefficient is a, and the machining speed is V. In accordance with this feature, regardless of the machining speed, the wire electrical discharge machine is capable of keeping the size of the electric discharge gap constant during machining.
In the above-described wire electrical discharge machine, the discharge state value acquisition unit may acquire, as the discharge state value, the reciprocal of the number of discharge pulses per unit time, or the discharge delay time period. In accordance with this feature, the discharge state value compensation unit does not have to change the coefficient α in accordance with the voltage applied to the inter-electrode gap, and the processing load in the discharge state value compensation unit can be reduced.
In the above-described wire electrical discharge machine, the control unit may subject the driving unit to a proportional control, an integral control, and a derivative control, and may thereby set the machining speed to a target machining speed, and may set, in accordance with the compensated value, at least one of a proportional gain of the proportional control, an integration time of the integral control, a derivative time of the derivative control, or the target machining speed. In accordance with these features, the wire electrical discharge machine is capable of improving the machining accuracy of the workpiece.
In the method of controlling the wire electrical discharge machine (10) configured to machine the workpiece (14) by generating the electric discharge in an inter-electrode gap between the wire electrode (12) and the workpiece, the method of controlling the wire electrical discharge machine includes the discharge state value acquisition step of acquiring, as the discharge state value, any one of the average inter-electrode voltage, which is a time average of the voltage applied to the inter-electrode gap, the reciprocal of the number of discharge pulses in the inter-electrode gap per unit time, or the discharge delay time period, which is a time period from when the voltage is applied to the inter-electrode gap until when electric discharging takes place in the inter-electrode gap, the discharge state value compensation step of compensating the discharge state value to obtain the compensated value in accordance with the machining speed, which is the relative speed of the wire electrode with respect to the workpiece, the driving step of causing the wire electrode to move relatively with respect to the workpiece by the driving unit, and the control step of controlling the driving unit (24, 26) based on the compensated value, and thereby keeping the size of the inter-electrode gap constant during machining, wherein, in the discharge state value compensation step, the compensated value is determined based on an equation in which the discharge state value defines a numerator, and the value obtained by exponentiation with the coefficient as the base and the machining speed as the exponent defines a denominator. In accordance with these features, the wire electrical discharge machine is capable of improving the machining accuracy of the workpiece.
In the above-described method of controlling the wire electrical discharge machine, in the discharge state value compensation step, the compensated value may be determined based on the equation Sc=S/α(1+V) where the compensated value is Sc, the discharge state value is S, the coefficient is a, and the machining speed is V. In accordance with this feature, regardless of the machining speed, the wire electrical discharge machine is capable of keeping the size of the electric discharge gap constant during machining.
In the above-described method of controlling the wire electrical discharge machine, in the discharge state value acquisition step, the reciprocal of the number of discharge pulses per unit time, or the discharge delay time period may be acquired as the discharge state value. In accordance with this feature, in the discharge state value compensation step, there is no need to change the coefficient α in accordance with the voltage applied between the electrode and the workpiece, and the processing load in the discharge state value compensation step can be reduced.
In the above-described method of controlling the wire electrical discharge machine, in the control step, the driving unit may be subjected to a proportional control, an integral control, and a derivative control, to thereby set the machining speed to the target machining speed, and in accordance with the compensated value, at least one of a proportional gain of the proportional control, an integration time of the integral control, a derivative time of the derivative control, or the target machining speed is set. In accordance with these features, the wire electrical discharge machine is capable of improving the machining accuracy of the workpiece.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/023907 | 6/24/2021 | WO |
