Principle of wire cut EDM

CNC wire cut EDM machine puts impulse voltage between electrode wire and
workpiece through impulse source, controlled by servo system, to get a certain gap,
and realize impulse discharging in the working liquid between electrode wire and
workpiece. Numerous tiny holes appears due to erosion of impulse discharging, and
therefore get the needed shape of workpiece( as show in figure 1-1).

Figure 1-1

Electrode wire is connecting to cathode of impulse power source, and workpiece is

connecting to anode of impulse power source. When workpiece is approaching
electrode wire in the insulating liquid and gap between them getting small to a
certain value, insulating liquid was broken through; very shortly, discharging channel
forms, and electrical discharging happens. And release huge high temperature
instantaneously, up to more than 10000 degree centigrade, the eroded workpiece is
cooling down swiftly in working liquid and flushed away. As show in figure 1-2

Figure 1-2 Diagram of Wire EDM process

Three basic conditions that wire cut EDM work correctly:

1. The gap between electrode wire and workpiece should be certainly

maintained in a required range. Within this range, not only impulse power can
break through insulating liquid to create spark discharging, but also the
eroded workpiece can be flushed away after discharging process. If gap is too
big, insulating liquid can’t be break through,, and there will be no spark
discharging; if gap is too small, short circuit is easy to happen, no spark
discharging neither.
2. The procedure should happen in the liquid with insulate capacity, for example
saponification and deionized water, the liquid could act as medium of
discharging channel and provide cooling and flushing.
3. Electrical discharging should be short time impulse discharging,. As with short
discharging time, the released heat won’t affect inside material of workpiece,
and limits energy to a tiny field and keep characteristics of cool machining of
wire cut EDM machine.
Types of sensors that involved in EDM :

1. Current sensors
- Detects electric current in a wire, and generates a signal proportional to
that current. The generated signal could be analog voltage or current or
even a digital output. The generated signal can be then used to display the
measured current in an ammeter, or can be stored for further analysis in a
data acquisition system, or can be used for the purpose of control.
- Use to detect current that use in EDM machine.

2. Capacitive sensors
- Detect both metallic and non-metallic targets in powder, granulate, liquid,
and solid form. This, along with their ability to sense through nonferrous
materials, makes them ideal for sight glass monitoring, tank liquid level
detection, and hopper powder level recognition.
- Use for monitoring the dielectric fluid level in the tank of EDM machine.
Principle of each sensors :

1. Current sensor

- Measuring a voltage in any system is a “passive” activity as it can be done

easily at any point in the system without affecting the system performance.
However, current measurement is “intrusive” as it demands insertion of
some type of sensor which introduces a risk of affecting system
performance.
- Current measurement is of vital importance in many power and
instrumentation systems. Traditionally, current sensing was primarily for
circuit protection and control. However, with the advancement in
technology, current sensing has emerged as a method to monitor and
enhance performance.
- A representational image of a current sensor

Figure 1-3 : A Representational Image of a Current Sensor

- Knowing the amount of current being delivered to the load can be useful
for wide variety of applications. Current sensing is used in wide range of
electronic systems, viz., Battery life indicators and chargers, 4-20 mA
 systems, over-current protection and supervising circuits, current and
voltage regulators, DC/DC converters, ground fault detectors,
programmable current sources, linear and switch-mode power supplies,
communications devices , automotive power electronics, motor speed
controls and overload protection, etc.

CURRENT SENSING PRINCIPLES

- A current sensor is a device that detects and converts current to an easily

measured output voltage, which is proportional to the current through the
measured path.
- When a current flows through a wire or in a circuit, voltage drop occurs.
Also, a magnetic field is generated surrounding the current carrying
conductor. Both of these phenomena are made use of in the design of
current sensors. Thus, there are two types of current sensing: direct and
indirect. Direct sensing is based on Ohm’s law, while indirect sensing is
based on Faraday’s and Ampere’s law.
- Direct Sensing involves measuring the voltage drop associated with the
current passing through passive electrical components.
- A diagram explaining the principle of direct sensing

Figure 1-4 : A Diagram Explaining the Principle of Direct Sensing

 - Indirect Sensing involves measurement of the magnetic field surrounding a
conductor through which current passes.
- A diagram illustrating the principle of indirect sensing

Figure 1-5: A Diagram Illustrating the Principle of Indirect Sensing

- Generated magnetic field is then used to induce proportional voltage or

current which is then transformed to a form suitable for measurement
and/or control system.

2. Capacitive sensors

- A capacitive sensor acts like a simple capacitor. A metal plate in the

sensing face of the sensor is electrically connected to an internal oscillator
circuit and the target to be sensed acts as the second plate of the
capacitor. Unlike an inductive sensor that produces an electromagnetic
field a capacitive sensor produces an electrostatic field.

Figure 1-6 : Diagram of Capacitive sensor

- The external capacitance between the target and the internal sensor plate
forms a part of the feedback capacitance in the oscillator circuit. As the
target approaches the sensors face the oscillations increase until they
reach a threshold level and activate the output.
- Capacitive sensors have the ability to adjust the sensitivity or the threshold
level of the oscillator. The sensitivity adjustment can be made by adjusting
a potentiometer, using an integral teach pushbutton or remotely by using a
teach wire. If the sensor does not have an adjustment method then the
sensor must physically be moved for sensing the target correctly.
Increasing the sensitivity causes a greater operating distance to the target.
Large increases in sensitivity can cause the sensor to be influenced by
temperature, humidity, and dirt.

Figure 1-7 : Diagram of oscillation of sensor in capacitive

- There are two categories of targets that capacitive sensors can detect the
first being conductive and the second is non-conductive. Conductive
targets include metal, water, blood, acids, bases, and salt water. These
targets have a greater capacitance and a targets dielectric strength is
immaterial. Unlike an inductive proximity sensor, reduction factors for
various metals are not a factor in the sensors sensing distance.
- The non-conductive target category acts like an insulator to the sensors
electrode. A targets dielectric constant also sometimes referred to as
dielectric constant is the measure of the insulation properties used to
determine the reduction factor of the sensing distance. Solids and liquids
have a dielectric constant that is greater than vacuum (1.00000) or air
(1.00059). Materials with a high dielectric constant will have a longer
sensing distance. Therefore materials with high water content, for
example wood, grain, dirt and paper will affect the sensing distance.
- When dealing with non-conductive targets there are three factors that
determine the sensing distance.
1. The size of the active surface of the sensor – the larger the sensing
face the longer the sensing distance
2. The capacitive material properties of the target object, also referred
to as the dielectric constant – the higher the constant the longer the
sensing distance
3. The surface area of the target object to be sensed – the larger the
surface area the longer the sensing distance

Other factors that have minimal effect on the sensing distance

1. Temperature
2. Speed of the target object

Short Term

- Capacitive proximity sensors use the variation of capacitance between the

sensor and the object being detected.
- When the object is at a preset distance from the sensitive side of the
sensor, an electronic circuit inside the sensor begins to oscillate.
- The rise or fall of such oscillation is identified by a threshold circuit that
drives an amplifier for the operation of an external load.
- A screw placed on the backside of the sensor allows regulation of the
operating distance.
- This sensitivity regulation is useful in applications, such as detection of full
containers and non-detection of empty containers.
- Capacitive proximity sensors usually have a larger sensing range than
their inductive counterparts, and it typically falls between 5 and 40
millimeters.
- The detection distance depends on plate diameter, as capacitive sensors
measure dielectric gaps. Many capacitive proximity sensors are equipped
with sensitivity adjustment controls for the sensing range, allowing them to
compensate for target object and application conditions.
Troubleshooting Method for each sensor.

Capacitive sensor

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Positioning error Noise or electrical

Re-route the cable away
or timeout interference from
from high power sources.
alarms. high-power cables.

The diagnostic
bit fluctuates
There is a poor
while the Clean, reseat connectors,
connection, or a
monitored and correct the cause of
signal interference
components are contamination.
from contamination.
idle.

Metal particles will not let the

There is metal
switch change state. Clean
particles on the face
metal particles from the face
of the sensor.
of the proximity sensor.

The diagnostic Align the trip flag or sensor,

The sense gap
bit does not make sure the gap between
between the sensor
change state. the face of the sensor and
face and the trip flag
the trip flag does not exceed
is not correct.
0.126 inces.

The cables or the I/O Troubleshoot the cables or

PCB is at fault. the I/O PCB.
 Metal particles will not allow
There is metal
the sensor to change state.
particles on the face
Clean metal particles from
of the proximity
the face of the proximity
sensor.
sensor.

The proximity sensor Check the proximity M12

connector has a connector make sure the

Alarm 145- loose connection. connection is tight.

147 AXIS LIMIT

SWITCH The cable from the
alarms. Check the proximity sensor
control to the
and extenstion cables for
proximity sensor has
damage.
an open connection.

Align the trip flag or sensor,

The sense gap
make sure the gap between
between the sensor
the face of the sensor and
face and the trip flag
the trip flag does not exceed
is not correct.
0.126 inces.

Metal particles will not allow

the sensor to change state.
Alarm 103-
There is metal This will cause the axis to
105 AXIS
particles on the face home in the opposite
SERVO ERROR
of the proximity direction, causing the axis to
TOO LARGE
sensor. hit the hard stop. Clean metal
alarms.
particles from the face of the
proximity sensor.
 False sensor trip due
Alarm 165- Check for metal chips around
to chip or home
167 AXIS ZERO the sensor or trip flag. Check
sensor problem, or
RETURN the sensor for damaged
the axis grid offset
MARGIN IS cables. Set the axis grid
parameter is not set
TOO SMALL offset parameter.
properly

Table 1

Malfunctioning Proximity Sensor

Figure 1-8 : The location of sensor in the machine

For 12 VDC proximity sensors, test the voltage at the proximity sensor. The 3-wire 5
VDC sensor receives voltage from the processor PCB. It is the same voltage that is
sent to the axis encoder. If the axis encoder works correctly, and there are no
encoder alarms, the sensor receives the correct voltage.

Always check for voltage from the back of the connector with needle-tip probes. If
there is voltage present at the proximity sensor, but it will not change status, the
sensor is at fault.
Signal Noise / Signal Interference

Figure 1-9 : Sensor connector pin and surface of the sensor

Make sure that the proximity sensor cable is not damaged, and that it is separated
from high-power spindle/axis/pump cables.

Make sure that the connectors and pins for the proximity sensors are not
contaminated. Make sure the pins have not backed out of the connector.

Check for contamination on the proximity sensor. Contamination on the face of the
proximity sensor can create a false signal. Fix the cause of the contamination.

Cable Damage

Figure 1-10 : Cable condition

Check the proximity sensor and extenstion cables for damage.

Current sensor

- Primary Test: Plug the probe into an interface and run the data collection program.
Use wire leads to connect the probe to a DC supply with a known resistance. Use a
voltage probe or voltmeter to measure the voltage. Compare the measured current
against the theoretical reading. We recommend a DC battery for this test, since
some DC power supplies may not deliver clean DC voltage.

- Secondary Test: The sensor contains a replaceable 10 A fuse. If the sensor stops
measuring current, you may need to replace a blown fuse. Turn the sensor over and
remove the four screws on the back. The fuse can be seen from the top. Use a small
screw driver to remove the fuse. Insert a replacement. One replacement has been
included with the sensor.