Abstract: A method of operating a machine tool, e.g., an electrical discharge machine, and a machine tool system with a machine, e.g. an electrical discharge machine, for machining a workpiece may include numerous configurable modules (DRIVE; GEN; CONTROL) to perform at least one of controlling, monitoring and carrying out of the machining of a workpiece. The modules (DRIVE; GEN; CONTROL) are arranged on the machine and are linked by a data network to a node for at least one of sending data to the node and receiving data from the node.

Abstract: Cutting device for spark-erosion machine wires in which, after passing through a machining region, the wire-electrode is cut up into sections which are disposed of as waste products into a recovery receptacle. The device comprises electrical contacts connected to a voltage/current source. The wire is subjected to a dielectric fluid whose flow rate is sufficiently high to generate a turbulent flow regime and cause random lateral movements of the wire which sporadically brushes against the contacts.

Abstract: A method for controlling a wire electric discharge machine comprising the steps of: determining of at least one predefined contour deviation (Esmax) of a predefined contour to be cut into the workpiece; determining a curvature of at least one geometry element defining at least one section of the contour to be cut into the workpiece; calculating a displacement (s) of an upper guide (WGU) and a lower wire guide (WGL) based on the predefined contour deviation (Esmax) and on the curvature of the at least one predefined geometry element; and setting the displacement (s) by moving the upper guide (WGU) relative to the lower wire guide (WGL) such that the wire electrode guided by the upper (WGU) and lower wire guides (WGL) is inclined in a current cutting direction of the workpiece during cutting of the geometry element into the workpiece.

Abstract: A method for controlling an electric discharge machining process, wherein a tool electrode is moved relatively to a workpiece with a working gap distance, wherein the process includes a current and at least one previous erosion cycle, the current and the previous erosion cycle each being divided into predetermined time intervals each including at least one discharge pulse, wherein similar working gap conditions are present within a time interval of the previous erosion cycle and of the current erosion cycle, and wherein subsequent erosion cycles are separated by a process pause cycle.

Abstract: Cutting device for spark-erosion machine wires in which, after passing through a machining region, the wire-electrode is cut up into sections which are disposed of as waste products into a recovery receptacle. The device comprises electrical contacts connected to a voltage/current source. The wire is subjected to a dielectric fluid whose flow rate is sufficiently high to generate a turbulent flow regime and cause random lateral movements of the wire which sporadically brushes against the contacts.

Abstract: An apparatus and a method of generating machining pulses for electrical discharge machining by discharge of at least one line applying a voltage to a working gap formed between a machining electrode and a workpiece, including the steps of: charging the line via a first charging circuit by a voltage source, discharging the line after ignition of the spark gap directly via a diode, without impedance matching, at the working gap, and recharging the line after a predefined pulse-off time.

Abstract: The methods and devices enable a reliable and rapid automatic threading process on spark-erosive wire-cutting machines with closed round guides without complicated entry of parameters. A heat-output control device with an optimized output characteristic curve is supplied from a DC voltage source of the erosion generator. Through an at least partial feedback loop of heating current and source voltage, the characteristic curve is modified in such a way that different wire types or different annealing lengths for the wire provide optimal results for stretching, straightening and separating the wire electrode without controlled intervention. With adaptive control it is possible to thread future wire types automatically without reprogramming.

Abstract: The invention relates to a method and device for electrical discharge machining (EDM) a workpiece by means of a train of machining pulses. During the machining time the machining pulses are applied to the working gap between workpiece and electrode, whereby an electrical parameter of the current machining pulse applied to the working gap is sensed, from which at least one characteristic value is derived. This is compared to a reference value, and depending on the result of the comparison, actions are initiated. The reference value is captured on the basis of at least one earlier machining pulse. The machining time is divided in time into sensing intervals during which reference values are captured from the applied machining pulses and into machining intervals during which no reference values are captured from the applied machining pulses.

Abstract: A wire cutting device for an electrical discharge machining (EDM) machine with a wire draw-off device, which moves a wire electrode along a feed direction into a cutting zone of the EDM machine; and with a deflection unit in order to deflect the wire electrode running in the feed direction into the cutting zone from the feed direction into a cutting area, in which at least one cutting edge acts on the wire electrode in the cutting area in order to cut it.

Abstract: The invention provides a method of operating a machine tool, e.g., an electrical discharge machine (4), and a machine tool system comprising a machine (4) for machining a workpiece wherein at least one of controlling, monitoring and carrying out of the machining of the workpiece is performed by a plurality of configurable modules (DRIVE; GEN; CONTROL), said modules (DRIVE; GEN; CONTROL) are arranged on the machine (4), and said modules (DRIVE; GEN; CONTROL) are so linked by a data network (6) to a node (5) for at least one of sending data to said node (5) and receiving data from said node (5).

Abstract: An apparatus and a method of generating machining pulses for electrical discharge machining by discharge of at least one line applying a voltage to a working gap formed between a machining electrode and a workpiece, including the steps of: charging the line via a first charging circuit by a voltage source, discharging the line after ignition of the spark gap directly via a diode, without impedance matching, at the working gap, and recharging the line after a predefined pulse-off time.

Abstract: A wire cutting device for an electrical discharge machining (EDM) machine with a wire draw-off device, which moves a wire electrode along a feed direction into a cutting zone of the EDM machine; and with a deflection unit in order to deflect the wire electrode running in the feed direction into the cutting zone from the feed direction into a cutting area, in which at least one cutting edge acts on the wire electrode in the cutting area in order to cut it.

Abstract: A method and apparatus for electrical discharge machining of a workpiece wherein an erosion pulse is applied on the tool electrode. During the time of the erosion pulse the voltage (Ue) set on the electrode is acquired, and the erosion pulse is interrupted, after an asymptotic behavior of the acquired voltage (Ue) or a value derived therefrom has been acquired. Before the interruption of the erosion pulse an increase of current may occur.

Abstract: A method and device for disturbance sensing in the drive system of a numerically controlled machine tool or similar device is disclosed, in which at least one drive motor for positioning of a machine part being moved such as an advance slide or an X/Y cross-slide is coupled via one or more transmission elements in which the position of the moving machine part is measured directly on the machine part and also indirectly in at least one location in the transmission chain. Direct and indirect position measured values are compared and the measured value comparison value is used to record a disturbance with consideration of the actual operating conditions, such as machining speed and acceleration/delay, optionally moved masses and machine-specific process forces upon fulfillment of a specific criterion.

Abstract: Devices and methods are disclosed for the contactless detection of a bar-shaped or wire-shaped processing electrode of a machine tool such as a spark erosion machine. The detection is based on measuring an impedance change in the measuring area, which is caused by the processing electrode moving through the measuring area. The impedance change is measured by one or more measuring electrodes disposed in the measuring area.

Abstract: A machine tool with a machine frame is disclosed. A first tool guide is provided on the frame to guide a tool to a first guide position. The first tool guide is a movable gantry carrier with a movable first sliding carriage. The tool guide can be moved with respect to the machine frame in a first plane along a first direction and in a second direction which is orthogonal with respect to the first direction. Furthermore, a second tool guide is provided on the machine frame to guide the tool to a second guide position. The second tool guide can be moved with respect to the machine frame in a second plane along a third direction and a fourth direction which is orthogonal to the third direction, independently of the first tool guide. Finally, a tool holder is provided on the machine frame to hold the machined part. The machined part is led between the first and the second guide positions of the tool. The second tool guide is a movable gantry carrier with a movable second sliding carriage.

Abstract: Devices and methods for threading a wire electrode in a wire erosion machine are disclosed. A feed-through channel is provided for producing a fluid jet within which the machining electrode is guided. One or more control devices are provided for varying the cross section of the feed-through channel and, thus, the cross section of the fluid jet.

Abstract: Methods and apparatus are disclosed for the processing of a work piece by electrical discharge, the processing being carried out with at least two wire electrodes. In the process, the offset of both the positions of the at least two wire electrodes relative to one another are determined, which positions the wire electrodes occupy upon their clamping, because of their angles of contact on a corresponding wire guide and their different wire characteristics at the level of the work piece. Further, the positions for the wire electrodes during the processing of the work piece after a change from one wire electrode to the next one are connected on the basis of the offset determined between these wire electrodes.

Abstract: A method and apparatus for electrical discharge or electrochemical machining of workpieces, in which a machining electrode is moved relative to a workpiece, the machining is performed in cycles, and the appropriate process parameters are adjusted for machining of the current cycle with consideration of process parameters of the current cycle. To improve this method and the apparatus to the extent that improved geometric machining accuracy is made possible without time losses, stored process parameters of at least one previous cycle are also considered for adjustment of the process parameters of the current cycle.

Abstract: A method and a device for controlling a number of machining processes on a machine tool with the help of a control device (20) that controls at least one tool for performing said number of machining processes under the direction of a control program, whereby the control program is created using a description of the tools required for performing the machining processes, and whereby the data for describing the tool are hereby divided in memories (24, 25) of the control device (20) into: (a) abstract tool data for describing a standard tool (V1, V2), and (b) specific tool data for correcting and/or adapting the abstract tool data to the actually used tool (R1, R2) or to machine-specific characteristics, whereby the tool description in the control program is obtained by linking the abstract tool data with the specific tool data.