Die-sinker EDM

Automation of
Die-sinker EDM

Hardware　 Software　 Core Technologies　 System Examples　

For Automation

Hardware

This section introduces equipment that works with machines to automatically transport and replace workpieces and electrodes.
The optimum system can be selected according to the size, mass, and number of the workpiece or electrode to be transported.

Image ▲ Example of AL40G+ & SR12 configuration

Workpiece and Electrode Transfer Device

SR12

Transfer equipment for applications that use a large number of small electrodes and small workpieces.

For applications that use small electrodes and small workpieces, we have included stockers and robots in a compact case.
Shelves are arranged in the front and rear of the main unit, and it is possible to customize the shelf spacing and the type of jig according to the customer's application.

Compatible models：AL40G+ / AL60G+

Max. transport load

Electrode: 7 kg, Workpiece: 9 kg

Pieces

Electrode: 60 pieces, Workpiece: 10 pieces

Positioning can be changed according to the type of machine supported

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System Support Tools

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The robot transfers the electrode and workpiece.

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Mr.Sodick

Process control is performed by the scheduler.

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System configuration example

Layout with a high degree of freedom is available, including tooling systems.

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Air blow box

You can automate the shape measurement and air blow processes after machining.

Image▲ Example of AL40G+ & ERC80 configuration

Erowa Robot Compact 80

ERC80

The pallet and electrode exchanges are done by the transfer robot.

A single robot station capable of conveying both electrodes and heavy workpieces achieves automation.
The compact layout saves space, and can be approached from either the left or right side, allowing for flexible system configuration.

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* The image is ATC-16E

Standard for automatic
electrode EXCHANGE

ATC

The optional ATC specifications provide a simple, space-saving configuration and even when there is no scheduler, the electrode shelf spacing is customizable and can be set freely.
As options for the AL+ series, we offer the stand-alone ATC units "ATC-16E" and "ATC-32E" that are installed on the left side of the machine, and the simple, space-saving ATC units "ATC-12S" and "Shuttle ATC" that are installed on the right side of the machining tank.
(For compatible models and specifications, please contact your sales representative.)

Adoption of
a tooling system that enables high-precision external setup

We provide Erowa ITS systems. These systems have a strong track record in efficient and automated EDM. This tooling system realizes high-precision external setup in automation systems, such as repeatability of 2 μm or less when clamping, indexing of 90° × 4, high clamping force, and direct operation from the electrode manufacturing process.

For Automation

Software

This section describes the software for continuous automatic operation and
the functions linked to the higher-level system that serves as the control tower.
In addition to this machine and NC unit, Sodick has developed all of these systems/software in-house,
enabling integrated manufacturing with no disruption to the engineering chain.

3D CAD/CAM system
developed and manufactured by Sodick

DiproSOLID

Die-sinker EDM

Machining programs can be created from 3D models of products.

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  • Obtain the machining position and centering measuring point directly, and create NC program from centering to machining.
  • The discharge projected area for each machining depth is calculated to search the optimum machining conditions.
  • By utilizing the three-dimensional model, the coordinate value input of the machining position can be omitted.
  • Since the centering measurement point is indicated on the threedimensional model, there is no error in entering the coordinate values.
  • EPX formats are supported.

Scheduler

Mr.Sodick

This scheduler supports automation without complicated tasks by managing design information (positioning, machining programs, position coordinates, workpiece information, etc.) and site information (measured values by external units and information from stockers) collectively.

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Simple scheduler function

LN Pro AI

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*The image shows SP power supply.

Basic scheduled operation is available with simple input by the LN Professional machining program creation support function, which is built into NC unit as standard. Several electrodes and workpieces can be automatically exchanged without advanced knowledge of setup, machining, and scheduler.
Scheduled operation with automatic power ON/OFF is also available, contributing to automation, labor saving, and energy saving.
In addition, API provision of LN professional engines enables robust and seamless cooperation with higher-level systems, including CAD/CAM systems.

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IoT

Operation monitoring application

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LQ Message is an operation monitoring application for network connection machines. You can use a personal computer to check the operating status of a Sodick machine tools. In addition, the specified mail address is equipped with a "notification function" that notifies you of completion of machining or alerts, and the machine operation status can be received by e-mail even if you are not at the production site. In particular, when automatic machining is executed for a long period of time, a notification of "completion of machining" is received, which is highly evaluated by the machining operators among the users.

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Monitoring up to 12 machines
by installing to a PC

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For Automation

Sodick Core Technologies

Automation of high-precision machining requires that the machine tools be
stable and not be deformed during prolonged continuous operation.
Sodick's machine tools adopt superior core technologies, including linear motors,
and have many achievements as machines suitable for automation.

AL+ series

Linear motor drive

Very high repeatability and long-term stability, which are features of linear motor drive, are the most important factors required for machine tools in "automation of manufacturing". Sodick's Die-sinker EDM is equipped with in-house developed and manufactured linear motor drives on all XYZ 3 axes.

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As it is a non-contact type that dispenses with the need for ball screws, degradation of mechanical precision traceable to wear on the ball screws and other effects does not occur throughout the machine life (10 years or more), maintaining the initial mechanical precision semi-permanently with no need for maintenance.

Linear Motor Drive EDM

EDM using a linear motor drive system suppresses concentrated discharge and secondary discharge that are caused by chip accumulation, etc., enabling any operator to perform constantly stable machining operation. This is an effect of high acceleration and high thrust linear jump by linear motor drive, enabling deep workpiece machining with narrow gap with no flushing and high quality.

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Accurate precision thermal displacement correction function TH COM

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Mechanical parts of machine tools that require high machining accuracy are deformed by the thermal expansion of metal even with slight temperature changes, and the machining accuracy is affected by the displacement of the position of the machining point. In order to automate machining, a machine that can produce stable machining results for 24 hours without deformation is required.
The AL+ series is equipped as standard with TH COM as overall temperature control and thermal displacement compensation functions. Automatic correction is performed by sensing air temperature, machining liquid temperature, and temperature of the machine structure. Preliminary data collection is not required, and correction is performed in real time to enable long-time operation regardless of season or environment.

High-performance NC unit manufactured in-house

In 1976, Sodick became the first company to install NC unit in EDM. Since then, Sodick has developed NC unit in-house. Therefore, there is no black box, and it is possible to construct an automation system with a high degree of freedom according to the equipment and machining.
By using the "Schedule operation function" built into the newest "SP power supply," automation can be started without the special software to control automation.

Table Down(Option)

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In recent years, there have been increasing demands for machining using rotary tables and for machining by installing clamping chucks on the tables for automation support. In conventional machines, this was addressed by raising the head, but with the AL40G+/AL60G+/AL80G+, the table were lowered to achieve specifications that satisfy both the "open height" and "dielectric level height," allowing the machine to flexibly accommodate a wide variety of setups that customers require.
Compatible models：AL40G+ / AL60G+ / AL80G+

Three-sided automatic up/down machining tank

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Equipped with a three-sided automatic vertical machining tank controlled fully automatically, ATC design has a high affinity with workpiece/electrode exchange systems using automatic electrode changers or robots and provides a simple, space-saving configuration that enables automated replacement of electrodes even in operations without a scheduler.
Compatible models：AL40G+ / AL60G+ / AL80G+

Supporting Productivity Improvement through Analysis, Survey, and Monitoring

Artificial Intelligence Maintenance Function "AIM"

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“AIM (AI Maintenance)” monitors and automatically diagnoses various machine conditions, such as machine operation status, maintenance status, and machine installation environment to improve machine availability, reduce the machining defect rate, and improve traceability.

On-machine measurement system with camera(option)

This system enables image measurement on the die-sinker EDM at the same level as that of a measuring microscope.

  • The 3 million-pixel color camera provides high-resolution images.
  • Digital zooming is easily available on PC display.
  • The icon menu and measurement navigation function allow intuitive operation.
Compatible models:AL40G+ / AL60G+ / AL80G+/ AL100G+

Main functions

One-Click Tool Function enabling one-touch measurement (automatic edge detection)

By simply clicking once near the edge you want to measure, the process from automatic tool setup to edge detection and calculation is done automatically.

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Fully featured navigation window for simple measurement

The system is equipped with the measurement navigation function to provide guidance on the selected measurement command and the status of measurement.

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Recording mode and run mode are useful for repeated measurement

Since the measurement procedure can be stored in a file and the program can be executed repeatedly, it is easy to measure many parts of the same shape without requiring any other key operations.

For Automation

System Example

From semi-automatic, which limits initial costs, to fully automatic, full-scale unmanned automatic operation,
we can build the optimum system according to the size, quantity, and machining time of the workpiece.

Theme I

“I want to keep the initial cost down and automate, and step up the conventional electrical discharge machining process!”

AL40G+ & SR12

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Point 1

Articulated Robot

Repeatedly performs smooth electrode and workpiece replacement for completely automatic machining of as many as 100 workpieces, or even more.

Point 2

Simple as possible

The electrode and workpiece holder sizes are unified to reduce the complexity of system construction.

Point 3

Optimized for small electrodes and small workpieces

SR12 is designed for applications that use a lot of small workpieces and small electrodes. The stockers and robots are housed in a compact housing. Shelves are arranged in the front and rear of the main unit, and it is possible to customize the shelf spacing and the type of jig according to the application.

Point 4

Hardware and software are all made of Sodick

This automation system combines the scheduler "Mr.Sodick" and CAD-CAM software "DiproSOLID". By developing all of these in-house, the engineering chain is able to produce products in an integrated fashion without interruption.

Theme II

“I want to automate high precision machining while utilizing the conventional technology!”

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Point 1

Standard Simple Scheduler Function

It can be operated using the simple scheduler function of "LN Professional" that comes standard with NC unit, making it possible to build a simple and easy-to-use system.

Point 2

Utilizes the ATC-32

Use the optional ATC unit to automatically exchange the electrode/workpiece. Because it does not use other robots, it is also easy to maintain.

Point 3

Specializing in precision machining of small items

Since transportation is by ATC, there is an upper limit to the volume of electrodes and workpieces, making this a system specialized for machining small items. The base is "AP1L" which demonstrates superiority in ultra-precision machining.

Point 4

Full Cover Specifications

Full cover specifications for both thermal displacement suppression and safety. The color of the three-color LED changes according to the operation status.

Theme III

“Achieving both process consolidation and onboard measurement while operating two machines in parallel.”

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Point 1

Easy and simple configuration ERC80

It uses a large-capacity ERC80 with the max. transport load 80 kg. Dynamic manufacturing is performed with two AL60G+ while automatically exchanging workpieces and electrodes of various sizes.

Point 2

Simple Presetter

Part of the external setup during machining is automated.
Accurate and stable machining can be performed continuously by measuring the next workpiece with the simple presetter.

Point 3

Orthogonal arrangement of two AL60G+

Multiple machines are arranged in a point symmetrical orientation around a single robot. The same NC program can be used with two AL60G+.

Point 4

Visualization System

A software system that constantly monitors program execution allows real-time monitoring of machining progress from a remote location.

Contact　 Die-sinker EDM List