Die-sinker EDM

Automation of
Die-sinker EDM

Hardware　 Software　 Core Technologies　 System Examples　

For Automation

Hardware

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High degree of freedom allows flexible operation

Articulated Robot

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Die-Sinker EDM and an articulated robot.
The articulated robot performs transportation including mounting/removing of electrodes and workpieces. From the layout of electrodes and workpiece stokers to air blow process and 3D measurement automation, system upgrades with the articulated robot are characterized by a high degree of freedom. The robot size is selected according to the weight of the transported object.

System Support Tools

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Electrodes and workpieces are transferred by a robot.

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Scheduler

Process control is performed by a scheduler.

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System configuration example

Flexible layouts including tooling systems are possible.

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Air blow box

Measurement of shapes and air blow processing after machining can be automated.

Adoption of
a tooling system that allows highly precise off-line setup

The EROWA ITS system we provide has an excellent track record in streamlining and automation in electric discharge machining.
This tooling system achieves highly precise off-line setup in automation systems. For example, it is possible to obtain repeat accuracy of 2 μm or less during clamping and perform 90° x 4 centering, and also because of its excellent clamping performance, operation is possible directly from the electrode manufacturing process.

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Replacement of electrode or workpiece is achieved with a simple configuration

SRC80

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A combination of the die-sinker EDM and SRC80 (Sodick Robot Compact 80).The AL series*is equipped with a three-sided automatic vertical machining tank controlled fully automatically and has a high affinity with workpiece/electrode replacement systems using automatic electrode changers or robots, allowing continuous automatic operation with high-precision and high-speed machining.
*AL40G/AL60G

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Sodick Robot Compact 80

Transportation of heavy workpieces is possible
Maximum transportation load: 80 kg
10 Positions of ITS 148 Pallet
33 Positions of ITS Holders
The starter kit of SRC80 has a type (option) with a scheduler “JMSPro”.

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* The image is ATC-16E

Standard for automatic
electrode replacement

ATC

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Even if there is no scheduler, the optional ATC specification enables automatic electrode replacement with a simple, space-saving configuration.
In the AL series, we provide options such as the stand-alone ATC units “ATC-16E” and “ATC-32E” installed on the left side of the machine, and simplified and space-saving ATC units “ATC-12S” and “Shuttle ATC” installed on the right side of the machining tank.
(For compatible models and specifications, contact the responsible sales personnel.)

For Automation

Software

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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  • Directly obtains machining positions and centering measurement points to create an NC program from centering to machining.
  • Calculates the discharge projected area at each machining depth and investigates the optimal machining conditions.
  • By utilizing 3D models, there is no need to enter coordinate values for machining positions.
  • Since centering measurement points are indicated on the 3D model, input errors of coordinate values do not occur.
  • Supports EPX formats.

Scheduler

A scheduler that supports automation without cumbersome operations by collecting and managing design information(positioning, machining programs, position coordinates, workpiece information, etc.) and on-site information (measurement values by external units, information from stockers).

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LN Professional - Simple Scheduler Function

The “LN Professional” machining program creation support function, which is equipped as standard on NC units, enables basic schedule operations with simple input. Requires no advanced knowledge of setup, machining, or schedulers, enabling automatic replacement of multiple electrodes and workpieces.

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*Images show a system with SP power supply

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AP30L ATC-16S full cabin (option)

Sodick-IoT

Collects the operating states of each machine, performs batch management and analysis from a remote location, and supports improvement in productivity.

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  • The IoT platform for machine tools which enables access from anywhere, using a smartphone, tablet, PC, or other device.
  • Can perform batch monitoring of machine states and machining rates, collect information about consumable parts or various sensors, and perform checks in real time. Visualizes and analyzes information about machines involved in production, reducing downtime and improving productivity.
  • NC screen can be checked from a remote location.
  • NC programs can be reserved and executed.
  • Service personnel of Sodick provide remote support for NC version upgrades and videophone and chat functions, etc.
  • Can connect to machine tools compatible with MTConnect or OPC UA, and monitor operating states, etc.

S-Viewer

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  • Software that patrols each NC unit at fixed interval to collect data.
    It can perform integrated management of operating states in registered NC units and improve machine operating rates.

For Automation

Sodick Core Technologies

AL series

Linear Motor Drive

High reproducibility and long-term stability, two characteristics of linear motor drives, are the most important factors demanded of machine tools in automation of manufacturing.
Sodick’s die-sinker EDM is equipped with an in-house developed and manufactured linear motor drive on all three XYZ 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.

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Discharge Machining of Linear Motor Drive

Discharge machining in the linear motor drive system suppresses concentrated discharge or secondary discharge that can occur due to chip accumulation, enabling constantly stable machining by any operator. This is an effect of the high-acceleration and high-thrust linear jump generated by the linear motor drive, enabling high quality deep machining of narrow gaps without jetting.

Ceramic Slider

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A lightweight, high-rigidity ceramic slider, manufactured in-house and which shows little thermal displacement, is used for the slide part of the Z-axis linear motor drive. It can stably maintain the precision of the initial shape over long periods of time.
Compatible models:AL40G/AL60G

Table Down(Option)

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In recent years, there has been increasing demand for use of rotary tables in machining, and machining by installing a clamp chuck on a table for automation purposes. While it has been supported by raising the head in the conventional models, in the AG40L, AG40LP and AG60L, lowering the table achieved a specification that satisfies both open height and machining fluid surface height, providing a flexible response to the multiple, diverse system setups customers have.
Compatible models：AL40G/AL60G

Three-sided Automatic Vertical Machining Tank

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Equipped with a three-sided automatic vertical machining tank controlled fully automatically, and has a high affinity with workpiece/electrode replacement systems using automatic electrode changers or robots, allowing continuous automatic operation with ultrahigh-precision and high-speed machining. Compatible models:AL40G/AL60G

Thermal Multi-fit(Option)

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System for estimating and correcting machine thermal displacement in real time based on temperature data measured in each machine part. It has the effect of reducing displacement by environmental temperatures by about 1/3 to 1/2.
Compatible models：AL40G/AL60G

※This catalog has been created based on AL series and AG series specifications. For information about other models, contact the responsible sales personnel.

For Automation

System Examples

Theme I

“Automate the conventional technologies and build a dynamic production system!”

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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

As Simple As Possible

Unifies the electrode and workpiece holder sizes, for a structure that reduces complexity when building a system.

Point 3

Automation of Air Blow Process

Machined workpieces are taken out by a robot, and machining fluid is removed in a drying station (air blow process).

Point 4

Change-over Station

Provides a change-over station that enables workpieces to be set and then grasped again from a different angle.
It can be effectively used in a restricted space, such as when machining using a rotating axis or supplementing the mobile range of the robot.

Theme II

“Automate high-precision machining
while taking advantage of the conventional technologies!”

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Point 1

Standard Simple Scheduler Function

Because it can be operated using the simple scheduler function of “LN Professional,” which is equipped as standard on NC units, you can build a simple system requiring no further maintenance after sale.

Point 2

Utilizes the ATC-32

Uses an optional ATC unit for automatic replacement of electrodes and workpieces. Because other robots are not used maintenance is easy to perform.

Point 3

Specializes in Small Object Precision Machining

Due to the ATC-based transport, this system has an upper limit to the electrode and workpiece volume, and specializes in small object machining. Based onthe AP1L, which delivers superior ultra-precision machining.

Point 4

Full-cover Specifications

Full-cover specifications ensure both suppression of thermal displacement and safety. The 3-color LED changes colors depending on the operating state.

Theme III

“Achieve both process integration and mechanical measurement
while running two models in parallel!”

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Point 1

SRC80 - Easy & Simple Configuration

The system adopts a SRC80 with a maximum transport load of 80 kg. Performs dynamic production with two AL60G units while automatically replacing workpieces and electrodes of various sizes.

Point 2

Simple Presetter

Automates parts of the off-line setup during machining. Simple presetter performs measurement for the next workpiece, enabling continuous accurate, stable machining performance.

Point 3

Forward/Reverse Positioning of Two AL60G Units

Centering around a single robot, multiple machines are arranged in a orientation of point symmetry. Runs the same NC program on two AL60G units.

Point 4

Visualization System S-HARMNY

Software system constantly monitoring program execution enables real-time checking of machining progress even from a remote location.

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