Multi-sensor electrode setup verification and diagnostics system for EDM Operation

In the mould making process, inevitable human error can arise with the authentication, verification, measurement, recording, programming and arrangement of electrodes prior to the electro-discharge machining (EDM) process. Cost-effective multi-sensor fusion techniques for the identification of electrodes; verification of the sequence and the precedence between the finishing, roughing and texturing tools used are proposed in this paper. The focus of research is to develop effective methodologies that can effectively eliminate the preventive errors. This in turn will further improve the performance of the EDM process, particularly for high value engineered moulds. Multi-sensor fusion techniques for the extracting and correlating the data from three sensors, namely - barcode scanner, radio frequency identification (RFID) reader and proximity sensor are used. In addition, a verification and diagnostics engine to verify the identity and sequence of the electrodes placed on the automatic tool change (ATC) prior to the actual spark erosion process is developed. With the implementation of the prototype, Fu Yu Corp Ltd has reported that it is now possible for two operators to manage five EDM machines concurrently (instead of 3 machines), representing a direct benefit gain of 66%.