Machine Introduction

The Wi-640S has XYZUV travels of 600 / 450 / 350 / 100 / 100mm, allowing it to handle relatively large workpieces. For workpieces with a thickness of 130mm, the maximum cutting angle can reach ± 22.5 degrees, enabling the Wi-640S to produce parts with inclined or complex shapes while maintaining high cutting precision. Additionally, the standard 0.5-micron optical scale ensures machining accuracy and cutting stability, improving the overall processing quality.

Beyond processing standard plastic and stamping molds, the Wi-640S has two unique application examples.

• Aerospace Circular Brake Pads: Due to the larger size of this workpiece, it is required to use Wi-640S for processing. Although it may seem like a simple single-cut operation, it requires the adjustment of multiple EDM parameters. This workpiece is composed of three different materials: stainless steel, brake composite material, and conductive adhesive. The adhesive and brake composite material contain non-conductive substances, which make the wire prone to breaking and leave noticeable wire marks during cutting. By utilizing advanced cutting technology, machining techniques, and rotational axis cutting, we have successfully achieved mass production of this aerospace consumable.
• Processing Large Heat Sinks: These heat sinks, due to their large size and tendency to deform during cutting, require very stringent processing conditions. The surface of the heat sink requires finishing cuts in addition to external cutting, with the shape consisting of several arch-like sections. However, due to the size and special shape, these arch pieces are prone to twisting and deformation during the machining process. Therefore, to ensure processing accuracy and quality, we must employ special techniques and processes.

High-Rigidity Structure:

• The machine body utilizes CAE (Computer-Aided Engineering) to simulate structural deformation of each axis during actual operation. Therefore, we use a high-rigidity T-shaped machine body structure to reduce load and thermal deformation issues, ensuring permanent mechanical accuracy.
• Casting was made from Meehanite cast iron, stress-relieved through heat treatment, it features a high-rigidity, symmetrically balanced design to reduce load and thermal deformation.
• The overall transmission structure employs a high-power AC (400W) servo motor, paired with Taiwan's PMI ballscrew and linear guides, this combination greatly reduces rotational errors. And with the adjustment of pitch compensation and backlash compensation in the control system, it ensures the precision of the machine's movement.

High-Precision Drive Shaft System:

The drive shaft uses highly precise "double nut" ball screws to achieve high rigidity, smooth operation, and minimal lead error. It is equipped with a high-torque, high-response AC (400W) servo motor, with an optional Fagor high-resolution optical scale for full closed-loop control. The optical scales are installed as close to the ball screws as possible, ensuring each axis maintains high precision, long life, and excellent stability.

Self-developed Wire Delivery System:

• The special structural design, combine with high-hardness ceramic pully, results in less wear and longer lifespan.
• With Japanese Panasonic AC servo motors, magnetic powder clutches, wire collection motors, and wire clamping mechanisms, the system can accurately make adjustment for instability caused by wire vibrations, ensuring stable wire delivery and low failure rates.
• The wire delivery system uses advanced constant tension motors for copper wire, it assures tension stability at all times and prevent copper wire entanglement caused by sudden breaks during normal operation.
• The wire delivery section utilizes a conduit-style collection structure. During threading, high-pressure fluid flow guides the copper wire to complete the threading process quickly within 3-5 seconds. Additionally, the use of high-quality ceramic wheel mechanisms ensures minimal wear over long-term use, eliminating the need for additional parts. Even ∅0.1mm copper wire can pass through easily without tangling.

Controller Performance and Features

● Right-angle Compensation: This function compensates the right-angle and parallelism of the XY and UV planes of the wire cutting machine. After compensation, the machine's right-angle accuracy can reach within ±1.5μm/300mm.
● Five Types of Corner Assist Lines: Contains additional corner assist line functions compared to other wire cutting machines:
0 - Intersection point
1 - <90 degrees (tangent) => Additional function
2 - <90 degrees (arc) => Additional function
3 - Tangent => Additional function
4 - Arc => Additional function
● Fuzzy G95 Control: Achieves more than 95% of manual operation speed, or even better.
● 212 Sets of Ultra-fine Machining Parameters: Provide 212 sets of ultra-fine machining parameters that can be adjusted according to different cutting needs.
● 10 Sets of Arc Deceleration Machining Parameters: Automatically switches machining parameters according to the arc radius set by the user.
● 10 Sets of Corner Deceleration Machining Parameters: Automatically switches machining parameters according to the corner angle set by the user.
● Ethernet Access Interface: Provides an Ethernet interface for accessing large amounts of machining data.
● 100 Sets of Coordinate System Records (Including G54 ~ G59): Traditional wire cutting systems only provide 6 sets of coordinate records (G54 ~ G59). JSEDM Wire Cutting System offers up to 100 sets of coordinate system records, which can be used for positioning movements.
● Dynamic 3D Graphical Display: Simulates graphics in 3D and allows zooming, regional enlargement, and rotation for detailed viewing.
● Touch Operation Interface: Uses a 15-inch high-resolution industrial-grade touch screen with an intuitive interface, significantly reducing operator learning time.
● Simple Operation Interface: Compared to the traditional DOS multi-layer operation menu, the Wire Cutting System simplifies the operation interface significantly and adds a hotkey area to centralize commonly used function keys, effectively reducing learning time and operation difficulty.
● Simplified Calibration Steps: Most functions only require 2-3 steps to start the calibration process, this simplifies the operation flow and shortening calibration time.
● Maintenance Information: Records six types of maintenance information, timely reminding the operator to replace consumables. The maintenance information includes: 1. Copper wire usage length, 2. Waste wire bucket usage time, 3. Water tank filter usage time, 4. Electron feeder usage time, 5. Ion exchange resin usage time, 6. Workbench usage time.
● POS Function: When this function is activated during machining, it automatically speeds up the machine when the workpiece is not in its path and resumes the machining speed once it touches the workpiece and cutting starts. This function greatly reduces machining time.

Gallery

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  2.5D image simulation allows customers to easily track the current cutting status, especially in taper cutting and abnormal shape with upper-lower shape difference.

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  Multi-functional calibration interface equipped with graphical explanations, making it easy for users to learn and operate.

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  Time-based maintenance records enable customers to replace consumables at routine time, enhancing machining stability.

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  Time-based maintenance records enable customers to replace consumables at routine time, enhancing machining stability.

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  With machining parameter data sheet, customers can refer to built-in parameters and select suitable machining conditions based on wire diameter, number of machining passes, and material type.