Wire electric discharge machine

Abstract

A primary power supply charges a capacitor by turning on a switching element and, upon completion of charging, turns off the switching element. Then, an AC pulse voltage is applied to the gap between a wire electrode and a workpiece by alternately turning on and off a switching element present in a secondary power supply. After a dielectric breakdown occurs between the wire electrode and the workpiece, the switching element is turned on to connect the capacitor so that the capacitor supplies a pulse current for machining.

Claims

1. A wire electric discharge machine for machining a workpiece into a desired shape by changing a relative position between a wire electrode and the workpiece while causing discharge by applying a voltage to a machining gap between the wire electrode and the workpiece, the wire electric discharge machine comprising: a secondary power supply including a DC power supply and a switching element, wherein the secondary power supply is configured to apply an AC pulse voltage; a primary power supply including a DC power supply, a switching element, and a discharge capacitor, wherein the discharge capacitor and the DC power supply are configured to be connected with each other and to be disconnected; a voltage detection unit disposed between the wire electrode and the workpiece; and a numerical controller, wherein the numerical controller includes a storage unit storing, in advance, a voltage value assumed when a dielectric breakdown occurs between the wire electrode and the workpiece, wherein the numerical controller is configured to compare a detected voltage value detected by the voltage detection unit with the voltage value stored in the storage unit, and wherein the numerical controller is configured to, as a result of the comparison, when the detected voltage value is smaller than the voltage value stored in the storage unit, determine that a dielectric breakdown has occurred between the wire electrode and the workpiece, and cause a pulse current to be supplied using the discharge capacitor of the primary power supply.

2. The wire electric discharge machine according to claim 1, wherein a polarity of the secondary power supply matches a polarity of a charge voltage of the discharge capacitor.

3. The wire electric discharge machine according to claim 1, wherein the numerical controller is configured to control machining of the workpiece in a first machining and a second machining subsequent to the first machining, and a machining energy for the second machining is smaller than a machining energy for the first machining.

4. The wire electric discharge machine according to claim 3, wherein both the primary power supply and the secondary power supply are configured to supply power in the first machining, and the secondary power supply is configured to supply power in the second machining, without the primary power supply supplying power in the second machining.

5. A wire electric discharge machine for machining a workpiece into a desired shape by changing a relative position between a wire electrode and the workpiece while causing discharge by applying a voltage to a machining gap between the wire electrode and the workpiece, the wire electric discharge machine comprising: a secondary power supply including a DC power supply and a switching element, wherein the secondary power supply is configured to apply an AC pulse voltage; a primary power supply including a DC power supply, a switching element, and a discharge capacitor, wherein the discharge capacitor and the DC power supply are configured to be connected with each other and to be disconnected, and the primary power supply is configured to charge the discharge capacitor bipolarly; a voltage detection unit disposed between the wire electrode and the workpiece; and a numerical controller, wherein the numerical controller includes a storage unit storing, in advance, a voltage value assumed when a dielectric breakdown occurs between the wire electrode and the workpiece, wherein the numerical controller is configured to compare a detected voltage value detected by the voltage detection unit with the voltage value stored in the storage unit, and wherein the numerical controller is configured to, as a result of the comparison, when the detected voltage value is smaller than the voltage value stored in the storage unit, determine that a dielectric breakdown has occurred between the wire electrode and the workpiece, and cause a pulse current to be supplied using the discharge capacitor of the primary power supply.

6. The wire electric discharge machine according to claim 5, wherein the numerical controller is configured to control machining of the workpiece in a first machining and a second machining subsequent to the first machining, and a machining energy for the second machining is smaller than a machining energy for the first machining.

7. The wire electric discharge machine according to claim 6, wherein both the primary power supply and the secondary power supply are configured to supply power in the first machining, and the secondary power supply is configured to supply power in the second machining without the primary power supply supplying power in the second machining.

8. The wire electric discharge machine according to claim 5, wherein a polarity of the secondary power supply matches a polarity of a charge voltage of the discharge capacitor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The objects and features described above and others of the present invention will become obvious from the descriptions in embodiments below with reference to attached drawings. Among the drawings:

(2) FIG. 1 shows a circuit that supplies a pulse current using a capacitor to finish machining according to embodiment 1 of the present invention;

(3) FIG. 2 shows the structure of a wire electric discharge machine according to the present invention;

(4) FIG. 3 is a flowchart showing processing according to embodiment 1 of the present invention;

(5) FIG. 4 shows detection voltage V1, charge voltage V.sub.C31 of a capacitor 31, and current I.sub.gap flowing between a wire electrode and a workpiece when the processing of the flowchart shown in FIG. 3 is performed;

(6) FIG. 5 shows a pulse generation circuit of a machining power supply of a wire electric discharge machine according to embodiment 2 of the present invention;

(7) FIG. 6 shows a circuit that supplies a pulse current using a capacitor to finish machining;

(8) FIG. 7 is a flowchart showing processing according to embodiment 2 of the present invention;

(9) FIG. 8 shows detection voltage V1, charge voltage V.sub.C31 of the capacitor 31, and current I.sub.gap flowing between the wire electrode and the workpiece when the processing of the flowchart shown in FIG. 7 is performed; and

(10) FIG. 9 shows a pulse generation circuit of a machining power supply of a conventional wire electric discharge machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(11) In the present embodiment, a method for supplying a pulse current using a capacitor to finish machining is described. An example of a circuit is shown in FIG. 1. Switching elements 28 and 29 are turned on by a primary power supply 27 to charge a capacitor 31 in advance and, upon completion of the charging, the switching elements 28 and 29 are turned off. Then, switching elements 23, 24, 25, and 26 in a secondary power supply 22 are turned on and off alternately to apply an AC pulse voltage to the gap between a wire electrode 32 and a workpiece 33 via power feed lines 34. After the pulse voltage causes a dielectric breakdown between the wire electrode 32 and the workpiece 33, a switching element 30 is turned on to connect the capacitor 31. This causes the capacitor 31 to supply a pulse current for machining. The energy stored in the capacitor 31 can be managed by the capacity and charge voltage and a stable pulse current can be supplied. Accordingly, a problem of the prior art technique can be solved: appropriate machining energy cannot be supplied for the second machining such as finish machining.

Embodiment 1

(12) The exemplary apparatus structure shown in FIG. 2 is achieved by adding a numerical controller 41, a calculation unit 42, a storage unit 43, a comparison unit 44, a voltage detection unit 45, a voltage detection lines 46 and 47, a power feed unit 49, and a wire electrode supporting unit 52 to a machining power supply 21 of the wire electric discharge machine in FIG. 1. Reference numeral 48 represents a power feed line.

(13) In the apparatus structure in embodiment 1, the secondary power supply 22 applies an AC pulse voltage and the capacitor 31 can be charged monopolarly.

(14) Processing is performed according to the flowchart in FIG. 3.

(15) After machining is started, the switching elements 28 and 29 in the machining power supply are first turned on to charge the capacitor 31 (sa01). Upon completion of the charging, the switching elements 28 and 29 are turned off (sa02).

(16) Then, an AC pulse voltage is applied to a wire electrode 50 and a workpiece 51. The switching elements 23 and 24 in the machining power supply are turned on (sa03). This connects the workpiece 51 to the positive polarity side of the secondary power supply 22 and the wire electrode 50 to the negative polarity side of the secondary power supply 22 and a voltage is applied to the gap between the workpiece 51 and the wire electrode 50.

(17) During application of the voltage, the voltage detection unit 45 detects the voltage between the workpiece 51 and the wire electrode 50. The detected voltage is sent to the numerical controller 41 and the calculation unit 42 converts the absolute value of the voltage value in the analog data format or the like into digital data.

(18) The storage unit 43 stores the digital data of the absolute value of voltage value Vth assumed when a dielectric breakdown occurs between the wire electrode 50 and the workpiece 51, as the threshold of a dielectric breakdown.

(19) If a dielectric breakdown does not occur, the power supply voltage of the secondary power supply 22 is applied to the gap between the wire electrode 50 and the workpiece 51 substantially as is. If a dielectric breakdown occurs, the wire electrode 50 is nearly connected electrically to the workpiece 51. Accordingly, the voltage is smaller than the power supply voltage of the secondary power supply 22.

(20) The comparison unit 44 compares the value converted by the calculation unit 42 with the data stored, in advance, in the storage unit 43 (sa04). As a result of the comparison, if it is determined that a dielectric breakdown has occurred between the wire electrode 50 and the workpiece 51 (YES in sa04), the switching elements 23 and 24 in the machining power supply are turned off (sa05). Then, the switching element 30 is turned on and a pulse current from the capacitor 31 is supplied to the gap between the workpiece 51 and the wire electrode 50 (sa06). After the capacitor 31 has been discharged, the switching element 30 is turned off and the processing returns to the beginning of the sequence (sa07).

(21) As a result of the comparison, if it is determined that a dielectric breakdown has not occurred between the wire electrode 50 and the workpiece 51 (NO in sa04), the processing is suspended for predetermined time t1 (sa08) and, if a dielectric breakdown occurs within predetermined time t1 (YES in sa04), the above operation is performed. If a dielectric breakdown does not occur within predetermined time t1 (YES in sa08), the switching elements 23 and 24 are turned off (sa09).

(22) Then, the switching elements 25 and 26 are turned on (sa10). This connects the workpiece 51 to the negative polarity side of the secondary power supply 22 and the wire electrode 50 to the positive polarity side of the secondary power supply 22 and a voltage is applied to the gap between the workpiece 51 and the wire electrode 50.

(23) During application of the voltage, the voltage detection unit 45 detects the voltage between the workpiece 51 and the wire electrode 50. The detected voltage is sent to the numerical controller 41 and the calculation unit 42 converts the absolute value of the voltage value (analog data) into digital data.

(24) The comparison unit 44 compares the value converted by the calculation unit 42 with the data stored, in advance, in the storage unit 43 (sa11). As a result of the comparison, if it is determined that a dielectric breakdown has occurred between the wire electrode 50 and the workpiece 51 (YES in sa11), the switching elements 25 and 26 in the machining power supply are turned off (sa12). Then, the switching element 30 is turned on (sa06) and a pulse current from the capacitor 31 is supplied to the gap between the workpiece 51 and the wire electrode 50. After the capacitor 31 has been discharged, the switching element 30 is turned off and the processing returns to the beginning of the sequence (sa07).

(25) As a result of the comparison, if it is determined that a dielectric breakdown has not occurred between the wire electrode 50 and the workpiece 51 (NO in sa11), the processing is suspended for predetermined time t1 (sa13) and, if a dielectric breakdown occurs within predetermined time t1, the above operation is performed. If a dielectric breakdown does not occur within predetermined time t1 (YES in sa13), the switching elements 25 and 26 are turned off (sa14). Then, the switching elements 23 and 24 are turned on again (sa03) to apply a voltage to the workpiece 51 and the wire electrode 50.

(26) FIG. 4 simply indicates the above flow. The three waveforms represent detection voltage V1, charge voltage V.sub.C31 of the capacitor 31, and current I.sub.gap flowing between the wire electrode 50 and the workpiece 51, respectively. The charging of the capacitor 31 starts at time t.sub.a and, upon completion of the charging, a pulse voltage with an alternating polarity from the secondary power supply is applied. If discharge by the secondary power supply does not occur within time t1, application of the voltage is aborted once and the voltage across the machining gap is set to zero. Then, a pulse voltage with the opposite polarity is applied. After that, this procedure is repeated. In this period, the charge voltage of the capacitor 31 is kept constant. If it is determined that the detection voltage becomes lower than threshold value Vth at time t.sub.b, the switching element of the secondary power supply is turned off. Then, the switching element 30 of the primary power supply is turned on to supply a pulse current I.sub.gap from the capacitor 31 to the gap between the wire electrode 50 and the workpiece 51. Upon completion of the charging, the switching element 30 is turned off and the processing returns to the beginning of the sequence.

Embodiment 2

(27) The exemplary apparatus structure shown in FIG. 6 is achieved by adding the numerical controller 41, the calculation unit 42, the storage unit 43, the comparison unit 44, the voltage detection unit 45, the voltage detection lines 46 and 47, the power feed unit 49, and the wire electrode supporting unit 52 to a machining power supply 37 of the wire electric discharge machine in FIG. 5.

(28) The difference between FIG. 1 and FIG. 5 is the circuit for charging the capacitor 31 of the primary power supply 27. Although the primary power supply in FIG. 1 can charge the capacitor only in one polarity direction, the primary power supply in FIG. 5 can charge the capacitor in both polarity directions.

(29) In the apparatus structure according to embodiment 1, the secondary power supply 22 applies an AC pulse voltage. On the other hand, in the apparatus structure according to embodiment 2, the capacitor 31 can be charged bipolarly.

(30) Processing is performed according to the flowchart in FIG. 7.

(31) After machining is started, the switching elements 28 and 29 in the machining power supply are first turned on to charge the capacitor 31 (sb01). Upon completion of the charging, the switching elements 28 and 29 are turned off (sb02).

(32) Then, the secondary power supply 22 applies an AC pulse voltage to the wire electrode 50 and the workpiece 51.

(33) The switching elements 23 and 24 in the machining power supply are turned on (sb03). This connects the workpiece 51 to the positive polarity side of the secondary power supply 22 and the wire electrode 50 to the negative polarity side of the secondary power supply 22 and a voltage is applied to the gap between the workpiece 51 and the wire electrode 50.

(34) During application of the voltage, the voltage detection unit 45 detects the voltage between the workpiece 51 and the wire electrode 50. The detected voltage is sent to the numerical controller 41 and the calculation unit 42 converts the absolute value of the voltage value in the analog data format or the like into digital data.

(35) The storage unit 43 stores the digital data of the absolute value of voltage value Vth assumed when a dielectric breakdown occurs between the wire electrode 50 and the workpiece 51, as the threshold of a dielectric breakdown.

(36) If a dielectric breakdown does not occur, the power supply voltage of the secondary power supply 22 is applied to the gap between the wire electrode 50 and the workpiece 51 substantially as is. If a dielectric breakdown occurs, the wire electrode 50 is nearly connected electrically to the workpiece 51. Accordingly, the voltage is smaller than the power supply voltage of the secondary power supply 22.

(37) The comparison unit 44 compares the value converted by the calculation unit 42 with the data stored, in advance, in the storage unit 43 (sb04).

(38) As a result of the comparison, if it is determined that a dielectric breakdown has occurred between the wire electrode 50 and the workpiece 51 (YES in sb04), the processing proceeds to step sb05 of the flowchart. The switching elements 23 and 24 in the machining power supply are turned off (sb05), the switching element 30 is turned on (sb06), and a pulse current from the capacitor 31 is supplied to the gap between the workpiece 51 and the wire electrode 50. After the capacitor 31 has been discharged, the switching element 30 is turned off (sb07). Then, the processing proceeds to step sb10 of the flowchart.

(39) As a result of the comparison, if it is determined that a dielectric breakdown has not occurred between the wire electrode 50 and the workpiece 51 (NO in sb04), the processing is suspended for predetermined time t1 and, if a dielectric breakdown occurs within predetermined time t1, the operation in step sb05 is performed. If a dielectric breakdown does not occur within predetermined time t1 (YES in sb08), the processing proceeds to step sb09 of the flowchart. The switching elements 23 and 24 are turned off (sb09). The switching elements 35 and 36 in the machining power supply are turned on (sb10). This charges the capacitor 31 in the machining power supply. The charge voltage of the capacitor 31 in this case has a polarity opposite to that used when the switching elements 28 and 29 are charged. After the capacitor 31 has been charged, the switching elements 35 and 36 are turned off (sb11). Then, the switching elements 25 and 26 are turned on (sb12). This connects, the workpiece 51 to the negative polarity side of the secondary power supply 22, and the wire electrode 50 to the positive polarity side of the secondary power supply 22, and a voltage is applied to the gap between the workpiece 51 and the wire electrode 50.

(40) During application of the voltage, the voltage detection unit 45 detects the voltage between the workpiece 51 and the wire electrode 50. The detected voltage is sent to the numerical controller 41 and the calculation unit 42 converts the absolute value of the voltage value (analog data) into digital data. The comparison unit 44 compares the value converted by the calculation unit 42 with the data stored, in advance, in the storage unit 43 (sb13).

(41) As a result of the comparison, if it is determined that a dielectric breakdown has occurred between the wire electrode 50 and the workpiece 51 (YES in sb13), the processing proceeds to step sb14 of the flowchart. The switching elements 25 and 26 in the machining power supply are turned off (sb14) and the switching element 30 is turned on (sb15), and a pulse current from the capacitor 31 is supplied to the gap between the workpiece 51 and the wire electrode 50. After the capacitor 31 has been discharged, the switching element 30 is turned off and the processing returns to the beginning of the sequence (sb16).

(42) As a result of the comparison, if it is determined that a dielectric breakdown has not occurred between the wire electrode 50 and the workpiece 51 (NO in sb13), the processing is suspended for predetermined time t1 and, if a dielectric breakdown occurs within predetermined time t1 (YES in sb13), the operation in step sb14 is performed. If a dielectric breakdown does not occur within predetermined time t1 (YES in sb17), the processing proceeds to step sb18 of the flowchart. The switching elements 25 and 26 are turned off and the processing returns to the beginning of the sequence (sb18).

(43) FIG. 8 simply indicates the above flow. The three waveforms represent detection voltage V1, charge voltage V.sub.C31 of the capacitor 31, and current I.sub.gap flowing between the wire electrode 50 and the workpiece 51, respectively.

(44) The charging of the capacitor 31 starts at time t.sub.c and, upon completion of the charging, a pulse voltage with an alternating polarity from the secondary power supply is applied. If discharge by the secondary power supply 22 does not occur within time t1, application of the voltage is aborted once and the voltage across the machining gap is set to zero. Then, before a pulse voltage with the opposite polarity is applied, the capacitor 31 is charged with a voltage with the opposite polarity. As described above, the sequence is repeated so that the polarity of the secondary power supply 22 matches the polarity of the charge voltage of capacitor 31.

(45) If it is determined that the detection voltage becomes smaller than threshold value Vth at time t.sub.d, the switching element of the secondary power supply 22 is turned off. Then, the switching element 30 of the primary power supply 7 is turned on to supply pulse current I.sub.gap from the capacitor 31 to the gap between the wire electrode 50 and the workpiece 51. Upon completion of the charging, the switching element 30 is turned off and the processing returns to the beginning of the sequence.