Abstract: The servo circuit is operable to monitor gap conditions on any number of working leads up to four at the same time. It further has the capability of responding to high voltage operating conditions and then reducing the gap voltage being sensed to an appropriate level. An analog stage is then employed to pick out the most valuable information being provided from the several gap leads. An amplifier of the FET type is used to provide high input impedance to the circuit. An absolute value circuit is further included which in either polarity will rectify the gap signal back to the positive level.

Abstract: A programmable system for controlling maximum machining current. A current limit is entered into the system together with the on time and off time desired. The system operates to use the entered on-time and current values, but the off time will be modified depending on the maximum current limit possible. This will protect the apparatus when an impossible combination has been entered by the operator. The duty cycle is checked against a maximum level such as 87% or a like upper limit.

Abstract: Included in the power supply is an output module connected to the gap which module uses a power FET. This module has its current output and the current to the gap controlled as a linear function of the control voltage applied to the gate of the FET. A suitable input means for the control voltage, includes manually controlled potentiometers, microprocessors, keyboards and the like.

Abstract: A protection system circuit which senses and responds to abnormal gap voltage condition. The circuit is operable in either positive or negative polarity of the gap. The circuit includes two branches, one relating to positive gap polarity and the other to negative polarity. The appropriate one of the two branches is selected by enabling one of two comparators in the respective branches.

Abstract: The system includes a standard servo feed arrangement in which responsive to gap voltage, servo feed is controlled for the electrode tool or alternately the workpiece.A further part of the system includes a gap voltage sensing lead and an analog to digital converter. At a predetermined point, a programmable computer is activated to provide an output signal through a digital to analog converter to influence the servo feed being controlled by the standard type servo feed system.The output from the programmable computer is weighted with respect to the output amplifier to provide a predetermined ratio of magnitude of control. A further embodiment of our invention is a system similar to the servo system described above, but in which the additional control over the servo feed system is exercised responsive to power level sensed in the EDM gap.

Abstract: A digitally controlled and free-running multivibrator for the power supply is used to supply machining power pulses of predetermined ON and OFF time duration. The pulse output from the digital multivibrator is passed through at least one intermediate drive stage to trigger an electronic output switch, which is operatively connected both to a main DC power source and the gap, to actually provide the machining power pulses thereto. Responsive to a predetermined drop in gap voltage, a digitally predetermined extended OFF time is added.

Abstract: An improved high voltage module for use in conjunction with a standard power module. The high voltage module includes a floating power supply in parallel with the standard power module and without ground connection included in the high voltage module are a plurality of stages of Darlington amplifiers. The two modules are opticoupled in the circuit with provision for fast turn-on and turn-off networks for the opticoupling network.

Abstract: Gap current is sensed and a voltage signal representative of gap current is integrated to provide a relatively stable DC voltage that is proportional to average current at the gap. A reference setting is made to which the average gap current is compared and, responsive to rise in current above that level, cutoff of the power supply will be initiated.

Abstract: The system responds to the frequency of pulses from the pulse generator or multivibrator. As the frequency of the pulses increases, they get closer together and the average voltage changes in a somewhat linear fashion. A final integrator amplifier stage is used to find the predetermined maximum current level for different frequency settings. Responsive to this level being exceeded, machining power is interrupted and the EDM operation interrupted.

Abstract: A power supply circuit including a multivibrator and a power output module. Drive signals are provided at low power level and an FET stage is used to provide a high wattage output to operate the power output module. The power output module provides machining power pulses to the gap through a plurality of series resistors so that peak current can be regulated in the module itself.

Abstract: A set of indicator lights, preferably of the light emitting diode type, are used to provide readout from the gap to indicate a gap open circuit condition, a gap normal machining condition, or a gap short circuit condition, respectively. Three lights are preferably contained in a vertical array to give the operator an exact indication of what type of machining is being carried on and hence inform him as to what correction should be made by way of servo feed adjustment, change of machining current, or the like.

Abstract: The servo circuit is operable both in a dual and in a single mode and includes an analog gate for multiple gap inputs. Dual operation is required where more than one gap is involved such as in the situation where multiple electrodes are carried by a common machine tool ram. In the servo operation, the unwanted information over a relatively wide voltage range is eliminated and the more significant voltage excursions around the 30 volt or gap breakdown voltage level are employed. This compensates for the non-linearity that is inherent in the electrical discharge machining gap.

Abstract: A servo feed control system providing arc sensing for each individual lead in a multiple lead set up. The lowest arc voltage of the several leads in the system determines the feed of the servo system through a hydraulic servo system or the like. Included are a pair of analog switches one of which is actuated responsive to gap polarity so that the system is conditioned to operate with equal facility at either gap polarity.

Abstract: A servo feed system for EDM in which feed of the electrode is controlled responsive to a gap voltage signal with appropriate feedback changes to control servo velocity and upfeed and downfeed gain as the gap voltage level changes. A further feature involves the imposition of a dither circuit between the gap voltage signal amplifier and the servo valve coil in such manner as to continuously apply dither in a manner independent of changes in gap voltage.

Abstract: A current selection and control system for providing uniform steps of machining current magnitude through a plurality of output modules all coupled to a common gap terminal and having individual amplifier stages. The current magnitude output of the modules is weighted in accordance with a binary code so that selection may be made directly through a binary thumbwheel switch and a gating system to enable selected amplifier stages and their associated modules.

Abstract: A protection circuit which senses and responds to an output transistor failure to provide appropriate power interruption to protect an electrical discharge machining apparatus. The circuit receives an input of either standard or reverse polarity from the gap. This signal is passed through a comparator stage where it is compared with a preset voltage level. Further inputs are provided in accordance with the polarity setting and from the multivibrator in such manner that an appropriate phase relationship is maintained depending on the preset polarity. A control signal is then generated to control a transistor switching device with an interrupt signal thus being furnished to turn-off the power supply. Also included in a different embodiment of the invention is a system whereby, in a multiple gap output module power supply, responsive to failure of an output transistor in any one of the output modules, the entire power supply is cut off.

Abstract: The system includes data input means for information relative to the material of the workpiece and the thickness of the workpiece. A read-only memory then provides information to a programmable counter so that off-time for the machining power pulses is appropriately provided for. In addition, there is manual preset means for setting the off-time to be provided during gap short circuit condition. An appropriate cut-off sensing circuit is operatively connected to the gap for sensing short circuit condition and initiating the pulse reduction but only for the duration of the gap short circuit condition.

Abstract: A system for controlling an electrical discharge machining apparatus in which there is an electronic output switch connected between a power source and an electrical discharge machining gap for providing to the gap machining power pulses of predetermined on-off time. The system further includes a current limiting stage for limiting the peak current provided to the gap at certain critical combinations of on-off time ratios so that possibility of gap short circuiting is substantially eliminated. This system further includes a programmable computer operable to receive a plurality of operator provided and memory stored data inputs, including one for controlling pulse on-time and the other as a current limiting signal for the current limiting stage. The system further includes a reference signal and a signal network connected to the gap for providing a feed-back of a gap voltage signal.

Abstract: A power supply circuit particularly useful in a multiple gap or a multiple electrode system in which multiple electrodes and a common workpiece or multiple electrodes and a like number of workpieces are selectively connected in circuit with a common DC source power supply circuit. A switching system is further provided for reversing the polarity of electrode relative to workpiece. A power supply circuit itself incorporates a specialized push-pull drive stage effective to drive the output stages in either polarity setting in such manner as to allow for negligible noise in the system. The drive system is one which generates triggering pulses effective to switch the output transistor bank in either polarity very rapidly and independently of the number of output leads which may be included.

Abstract: The system includes a pair of stepping motors for controlling relative movement of the wire electrode relative to the workpiece with the velocity of movement being controlled as a function of gap voltage. For this purpose the system includes a voltage controlled oscillator having its input coupled to the machining gap and its output interconnected with the drive circuits for the two stepping motors. The system further includes a divider stage which becomes operable in the system responsive to drop of voltage indicating gap short circuit condition so that a drastically reduced number of stepping pulses are provided to the motors throughout the duration of the gap short circuit condition. After removal of the gap short circuit condition, an increase in voltage allows changeover through several different gating stages to again return the output of the voltage controlled oscillator to its normal frequency range so that the feed of the electrode relative to the workpiece is again continued.