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<p>In micro-electrical discharge machining (micro-EDM), it is crucial to maintain an optimal gap between tool electrode and workpiece for stable and continuous machining. Accurate and real-time state detection is a prerequisite for the implementation of gap servo control. A novel monopulse recognition-based state detection method for self-adjustable servo control is proposed. This detection method discriminates pulse types with high precision by utilizing unique monopulse characteristics. The detection circuit avoids capacitive filtering but integrates multi-level nanosecond comparators to overcome the trade-off between accuracy and real-time performance caused by improper time constant RC in the conventional average voltage detection method. The self-adjustable servo control iteratively refines the servo speed to approach the optimal value, forming a macroscopic stair-stepping pattern complemented by microscopic fine-tuning self-adjustment. Experiments of micro-hole machining demonstrate that it achieves a significant 42% improvement in machining efficiency with a 3% increase in the effective discharge ratio compared to conventional threshold servo control. Applying to micro 3D structure scanning, a precise and robust electrode wear model considering varying wear rates at different scanning positions is established, forming an effective-pulse based depth-constrained algorithm insensitive to scanning speed. It effectively suppresses the recurrence of crater and bump errors on the machined surface.</p>

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Monopulse recognition-based interelectrode state detection for self-adjustable micro-EDM servo control

  • 期刊论文

  • 发表日期：

    2025年6月13日

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  • Peiyao Cao,
  • Hao Tong,
  • Yong Li,
  • Baoquan Li,
  • Feng Yu

摘要

In micro-electrical discharge machining (micro-EDM), it is crucial to maintain an optimal gap between tool electrode and workpiece for stable and continuous machining. Accurate and real-time state detection is a prerequisite for the implementation of gap servo control. A novel monopulse recognition-based state detection method for self-adjustable servo control is proposed. This detection method discriminates pulse types with high precision by utilizing unique monopulse characteristics. The detection circuit avoids capacitive filtering but integrates multi-level nanosecond comparators to overcome the trade-off between accuracy and real-time performance caused by improper time constant RC in the conventional average voltage detection method. The self-adjustable servo control iteratively refines the servo speed to approach the optimal value, forming a macroscopic stair-stepping pattern complemented by microscopic fine-tuning self-adjustment. Experiments of micro-hole machining demonstrate that it achieves a significant 42% improvement in machining efficiency with a 3% increase in the effective discharge ratio compared to conventional threshold servo control. Applying to micro 3D structure scanning, a precise and robust electrode wear model considering varying wear rates at different scanning positions is established, forming an effective-pulse based depth-constrained algorithm insensitive to scanning speed. It effectively suppresses the recurrence of crater and bump errors on the machined surface.