For Automation
This section introduces equipment that works with machines to automatically transport and replace workpieces.
The optimum system can be selected according to the size, mass, and number of the workpiece or electrode to be transported.
▲ ALN400G iG+E & Articulated Robot configuration exampleHigh degree of freedom and flexible support
The articulated robot carries workpieces.
To prevent rust on workpieces, which is mainly a problem with water dielectric, it is necessary to dry the workpieces thoroughly or spray an antirust oil. As features of the system upgrading with articulated robots, the degree of freedom in the layout of each device is high, and it is possible to automate the air blowing process (drying station) and access to the rust prevention spray device.
The tooling system for wire-cut EDM is selected
according to the shape and application of the
workpiece, which enables flexible set-up work and
cooperation among machines, thus improving
productivity of the whole machining process.
Workpiece exchange is automated,
large capacity and space saving
Compared to articulated robots, many robots have a larger loading capacity and can transport various types of workpieces even in a reduced space.
For wire EDM, when a large number of workpieces are being machined, continuous machining is possible by setting as many workpieces as possible beforehand on the machining table. However, in this case, the NC program to be created becomes complicated, and the workpiece setup also requires a long work time.
Automation of workpiece transport enables optimum workspace use, a drastic shortening of setup time on the machine, improving machine operating rate.
Flat chuck
When compared with other machine tools, wire-cut EDMs require a special setup.
Use of tooling in response to each utilization enables flexible setup operations and greatly improves productivity in wire-cut EDMs.
Electrode setup by chuck adapter
Mixed setup by clamping frame
Circular parts setup by prism holder
Off-line measurementFor Automation
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.
Scheduler
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.
It can be linked with DiProWin, and can be used for workpiece positioning operation or scheduled as it is after programming.
In-house development and manufacturing 2-D CAD/CAM System
This is a CAD/CAM system for wire-cut EDM that can cope with a wide variety of conditions, developed with the aim of shortening lead times at the mold designing and manufacturing sites.
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. It also
has a notification function that will notify you of completion of
machining and alerts to the email address you set.
You can receive the machine operation status 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.
For Automation
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.
As it is a non-contact type that dispenses with ball screws, degradation of mechanical precision caused by worn ball screws and other effects does not occur throughout the machine life (10 years or more); it maintains the initial mechanical precision semipermanently which is maintenance-free.
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 wire-cut EDM is equipped with linear motor drive on their XYUV 4 axes as standard.
Broken line connection and automatic restart strongly support automatic operation for a long time. We boast a high wiring ratio regardless of whether in air or water.
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.
Latest "SPW power supply" is equipped with various functions
to improve working efficiency, such as "schedule operation
function" which can continuously execute several NC programs
at a specified date and time, and "Heart NC" which is a twodimensional
program creation function which can create
machined shapes, in addition to functions which can perform
setup and correction by NC codeless such as auto-correction
of inclination and distortion of workpieces and optional threepoint
automatic measurement.
This core removing device has a simple structure that prevents the workpiece cut out after machining from falling and collects it automatically. The core removing can be automated without misalignment even for precision workpieces.
Recommended for this case
This is a system for measuring shape accuracy by shooting a workpiece placed between a camera mounted on the upper guide and a backlight mounted on the lower guide. Non-contact leads to human error prevention, and can measure the part where the probe and reference ball do not enter. It can also be compared to DXF files.
Measure and check the results on NC screen.Always record machine temperature change and diagnose effects on machining in real time. It also monitors changes in the amount of wire remaining and the specific resistance of the dielectric, and proposes replacement of consumables. This is a maintenance function that leads to a reduction in the defect rate and an improvement in traceability.
“ TH COM (Thermal Commit),” capable of sensing the temperature of each part of the machine and utilizing the accurate compensation and various diagnostic functions, minimizes temperature changes in the installation environment and thermal displacement during high-speed driving.
For Automation
From semi-automatic, which limits initial costs, to fully automatic, full-scale unmanned automatic operation,
we can build the optimal system according to the size, quantity, and machining time of the workpiece.
Theme I
Point 1
Machining with the ultra-precise model "AL400P iG+E"is automated using a large-capacity ERC80. Several types of workpiece pallets are prepared according to the machining size. Dynamic machining is performed with two AL400P iG+E.
Point 2
Multiple machines are arranged in a point symmetrical orientation around a single robot. The same NC program can be used with two AL400P iG+E.
Point 3
Utilizes a ceramic and simple presetter for setting workpieces and checking accuracy as external setup.
Point 4
Stable automatic wiring is essential for long-term continuous machining. AL series-based "FJ-AWT" is a high-performance automated wiring system that can connect wire electrodes stably to workpieces that are held on pallets in a "bottom open/ submerged" condition.
Theme II
Point 1
When machining a large amount of workpieces, set-up time occurs every time a workpiece is replaced, even if the machining per point is short time. By automating the transfer, mounting, and removal of workpieces with robots, the setup time is drastically shortened, enabling labor-saving and improvement of the machine operation rate.
Point 2
We use "rust-less", an option for rust prevention and corrosion prevention of workpieces using two approaches: electric action and chemical action.
Point 3
Workpieces after machining are taken out by the robot, and dielectric liquid is removed by the air blow process (drying station).
Point 4
A software system that constantly monitors program execution allows real-time monitoring of machining progress from a remote location.
Theme III
Point 1
Articulated robots excel in transporting lightweight workpieces with a high degree of freedom. Taking advantage of these features, workpiece transfer, attachment/detachment, and finishing to the rotary axis are automated by synchronous machining with the indexing rotary shaft.
Point 2
In oil machining, there is no rust generation or corrosion of cemented carbide material in principle. Final finishing is possible in cutter shapes that cannot be polished. Oil dielectric itself is also excellent in oxidation resistance, and stable machining performance is demonstrated even in long-time continuous machining.
Point 3
Onboard measurement with a touch probe minimizes machine differences that tend to occur in external setup, enabling precise machining.
Point 4
AP series is an ultra-precise model that offers high performance in all environments. The adoption of a portal structure and an arm suspension structure and a linear motor drive system that achieves high speed and high response minimizes mechanical displacement and friction caused by mass movement.