Wire-Cut Flat Linear Electric Discharge Machines
Terminology (common use):
Electric Spark Discharge Wire-Cut Machine = Wire-Cut EDM = EDW
| Models: | NP400L | NP500L | NP600L |
| XY travel | 400 × 300 mm | 500 × 300 mm | 600 × 400 mm |
| UV travel | 80 × 80 mm | 120 × 120 mm | 160 × 160 mm |
| Z travel | 220 mm | 310 mm | 410 mm |
| Workpiece | max 500 kg | max 600 kg | mx 800 kg |
Please contact us for the
actual prices for the moment!
Ball screw drives are sofisticated structures with a complex chain of multi-stage conversion of energy into rotational motion and then rotational motion into linear motion – with backlashes, a large dead zone and uneven coarse feeds. There is a long delay from the command pulse to the start of movement at the start and each reverse. And if in such a drive there are also reductors (belt or gear), then the delays grows almost into idle time-outs:
command impulse
interaction energy
of magnetic fields
rotation of the motor rotor
(functioning of a belt
or gear reducer, if any)
ball-screw rotation
ball-screw backlash play
linear movement
(ball-screw movement)
A long distance
from a command
to execution!
Linear drives with flat (planar) linear motors are an extremely simple construction with non-contact transmission of force, a direct drive without any kinematic chain for converting energy into motion and rotational motion into linear motion, without backlash, dead zone and uneven bumpy feeds. In fact, the moving part of a linear motor is also a mover. All that happens when processing each motion is:
command impulse
interaction energy
of magnetic fields
linear motion
And that is all!
Barely moments
from a command
to execution!
Linear Motors
correct the gap
100s times per sec
with feedback response
and linear scales resolution of
10 nanometers
Ball screw drive and a ball-screw construction
- Inferior acceleration – deceleration
- Backlashes, lost motions, large dead zone. Stick-slips.
- Shape distortion at the points of axes feed changes with especially negative effect on roundness
- Rapid wear + loss of positioning accuracy.
Flat Linear Motors
- Nearly instant acceleration-deceleration
- Free of backlashes, free of lost motions, negligable dead zone. Free of stick-slips.
- Lack of shape distortion at the points of axes feed changes
- Screw-less drive with Longevous Precision
Flat Linear Motors vs Shaft Motors
huge difference:
Some other machine-tools
∅28∼30 мм
Illustration from a manual of the shaft motor manufacture NPC
Due to the longitudinal waves and the heterogeneity of the parameters of the individual magnets and their parts, the shaft deforms (plays)
EXCETEK – Flat Linear
Flat (Planar) Linear Motors or Shaft Motors: Your Choice?
Main disadvantages of the shaft motors:
- thrust deficit (ЕМ coil are coreless!)
- heat sink problems (or its absence!)
- thrust is generated at a distance from the plane of movements – at any movement the motor pulls one side of the table down and the other – up
- multidirectional runouts of the magnetic shaft and
dynamic asymmetry of the gap (thrust vector
“dances” chaotically from the direction of the feed!); - flimsy design (the shaft is attached only at the ends in
tension and requires retensioning intermittently).
Main advantages of the flat Linear Motors:
- reliability and longevity
- thrust is generated in a plane
close to the linear guides of the carriages; - highest dynamic precision throughout the entire operation
(the thrust vector coincides to the greatest extent with
the feed direction); - high power and thrust due to core EM coils design;
- perfect heat sink – the block of electromagnetic coils is
attached with the entire plane to massive structural
elements with high heat conductivity; - extra rigid structure;
- unalterably constant unchanging gap
Wire-Cut EDM with Flat Linear Servo
rigid flat linear motors
- Hi-thrust, high efficiency, low energy consumption
- Flat linear motors provide superb contour accuracy and super finish cutting
- NP wire-cut machine-tools are equipped with 0,01 µ (10 nano) scales
1,0 µ
0,01 µ
10 nano
The extra wide base of NP-series Wire-Cut EDMs prevents the work table from sagging at the extremes of travel ensuring horizontality precision.
NP-series Wire-Cut EDM – water cooling of the lower arm:
The water cooling (thermostating) of the lower arm (lower wire guide support arm) provided by the hydro unit prevents its thermal expansion in the process of electric spark cutting, increasing the final accuracy of the processed part.
LM roller guides guarantee the highest precision and stability.
The sturdy cast iron Meehanite base is designed using the Finite Element Analysis (FEM) method, which ensures rigidity and stability of the structure.
In 1990s Mr. Yoshikazu Matsuo invented and patented the world first automatic wire-threading device with wire annealing (Japanese Patent # 特許第2686796号). In later years his ingenious invention has been deeply modified and greatly improved.
NP-series Wire-Cut EDM AWT is the latest modification of the reliable wire threading mechanism created by Mr. Y.Matsuo.
Linear Wire-Cut EDMs
+ Fast (10 seconds!) & Reliable
Automatic Wire Threading (AWT)
New W600i Controller
Soft Version W20A
- CPU = Intel j1900
- Reliable industrial version of Windows
- CPU efficiency increases up to 600%
- Large 19″ sense-touch screen
- Graphics speed up to 600%. For a program of 30,000 blocks, the compilation speed is greatly different from the old version: 17 sec compared to 123 sec
- New generation PCB
Hi-Precision:
SKD-11;
t = 20 mm;
1 rough cut + 2 finishing;
contour accuracy 0 ∼ -2µ
Technical Maintanence and Support:
Innovation-Technical Center
of SodicoM-BG EOOD in Pomorie, Bulgaria
Excetek EDW
construction
features
DPM - Digital Power Management
The digital signals of the spark discharge density and state are fed to the CNC controller to facilitate calculation of the discharge area according to the discharge capacity,
Thus DPM enhances the precision of the discharge energy management and controls wire tension and water flow. The system improves the speed and accuracy especially in step shape parts machining.
| Effects of DPM (step shape part cutting) | Mode | с DPM | без DPM |
| Time | 39 min | 58 min | |
| Accuracy | ±3 µm | ± 15 µm |
Stable Discharge Module
Continuous cutting of 50 holes with shape accuracy control of up to 4 μm (inner)
Results of an official SGS (Société Générale de Surveillance) test:
achieved accuracy images
PRECISION: Pitch Error
X pitch error
Workpiece: SKD-11
Thickness: 30 mm
Number of cuts: 4
Y pitch error
PRECISION: Roundness
Workpiece:
tungsten carbide
Thickness: 50 mm
Wire electrode:
∅0,2 mm
Number of cuts:
1 rough + 2 finishing
Roundness = 2.6 µm
In 1990s Mr. Yoshikazu Matsuo invented and patented the world first automatic wire-threading device with wire annealing (Japanese Patent # 特許第2686796号). In later years his ingenious invention has been deeply modified and greatly improved.
NP-series Wire-Cut EDM AWT is the latest modification of the reliable wire threading mechanism created by Mr. Y.Matsuo.
Linear Wire-Cut EDMs
+ Fast & Reliable
Automatic Wire Threading (AWT)
Standard Accessories:
- XY linear scales 10 nm (0.01 µm)
- AWT (Automatic Wire Threading)
- Brass wire electrode (× 1 reel / 3 kg)
- Clamping tool (× 1 set)
- Ion exchange resin (× 10 liters)
- Vertical alignment jig (× 1 set)
- Paper filters (× 2 pcs)
- Diamond guides (× 2 pcs)
- Upper & lower flushing nozzles (× 2 sets)
Options:
- Clamping beam
- Super Finish Circuit (< Ra=0.2 µm)
- Rotary indexing table of W-axis
- AVR 15кVA
- Jumbo Feeder L-50A
- SMS option
- Signal Tower
- Remote Monitor System
- Auto Measuring System
Specifications | NP400L | NP500L | NP600L |
| Max workpiece | 750 × 550 × 215 mm | 850 × 550 × 300 mm | 1000 × 700 × 345 mm |
| Max workpiece weight | 500 kg | 600 kg | 800 kg |
| XY stroke | 400 × 300 mm | 500 × 300 mm | 600 × 400 mm |
| UV stroke | 80 × 80 mm | 120 × 120 mm | 160 × 160 mm |
| Z stroke | 220 mm | 310 mm | 410 mm |
| Wire diameter | ∅ 0,15 ∼ 0,30 mm | ||
Simultaneous axes control | XY – flat linear drives + UVZ AC servo | ||
| Max taper angle | ±22°/80 mm (wide diamond guides + nozzles) | ±26°/80 мм (wide diamond guides + nozzles) | ±30°/80 мм (wide diamond guides + nozzles) |
| Machine dimensions | 2260 × 2625 × 2100 mm | 2500 × 2650 × 2160 mm | 2670 × 2965 × 2300 mm |
| Machine weight | 3050 kg | 3350 kg | 4700 kg |
| Water tank volume | 650 liters | 750 liters | 900 liters |
| Paper filter | 2 | ||
| Deionizer | automatic | ||
| Water cooler | automatic | ||
Machine-Tool Dimensions
