Sodick Showcases Wire EDM Linear Motor Drive Technology

Sodick, Inc. (Schaumburg, IL) hosted a Smart Technology Event on October 3-4 at their corporate headquarters in Schaumburg that introduced over 200 attendees to a new range of rigid linear motor driven Wire EDM machines.

The linear motor drive technology on the SL Series Wire EDM models contains the same components as a servo motor that uses magnets and copper coils. A linear motor is an uncoiled servo motor. As amperage enters the coils, it creates force that is repelled against the magnets. The motor is the driving force that eliminates the need for ball screws.

The linear motor technology on the SL Series Wire EDMs is based on electronic drives with an option that improves accuracy, repeatability, speed and acceleration. Since linear motors are a direct electronic drive with no mechanical parts, they do not have the backlash and wear problems ball screw drives may have.

Data transmission to linear motors on the SL Series is instantaneous with the use of a motion controller. Over shoot and under shoot does not occur since glass scales are attached to the axis to measure positioning so the exact position is always known.  Linear motors produce virtually no vibration and zero backlash because they are directly driven.

Users are guaranteed positioning accuracy for ten years on these SL Series Wire EDMs, along with all their other linear motor driven Wire and Sinker EDMs. This compares to using traditional ball screws, where the motor drives start to lose accuracy after only two years and after five years of constant use the ball screws need to be replaced. On an SL Wire EDM, this is not an issue.

This technology was on display during the event with the SL600G Wire EDM, which has rigid linear motor axes drives coupled with glass scales on the X, Y, U and V axes to ensure precision cutting and positioning accuracy. These X, Y, U and V linear motor drives have no backlash. The rigid linear motors have an optimum flat design. The machine castings support the linear motor to achieve ideal linear performance for precision machining.

The SL600G has X-, Y-, Z-axis travels of 23.62 in (600 mm), 15.75  in (400 mm) and 13.78 in (350 mm). U- and V-axis travel is 5.91 in x 5.91 in (150 mm x 150 mm). Wire diameter used on the SL600G ranges from 0.002 in to about 0.012 in (0.05 mm to about 0.30 mm). The machine can handle workpieces weighing up to 2,204 lb.

The new Sodick Control SPW (Smart Pulse Wire) uses the Windows 7 operating system with an enhanced 19 in FT multi-touch screen that operates like a tablet. The operation screen can switch between the traditional screen and the tablet style screen. Screen layouts can be customized by the operator to suit specific working preferences. NC programs are supported with 2D and 3D graphics. Maintenance screens show the status of the machine and remote access is possible for maintenance and supervision.

A Smart Pulse Generator reduces the number of cuts and time necessary to achieve the required accuracy and surface finish – a financially competitive advantage for shops. The standard Intelligent Q³vic EDW technology imports 3D CAD files. This automatic programming system also detects the profile of a workpiece for Wire EDM machining and extracts the machining contour to save a significant amount of programming hours.

The Sodick Motion Controller (K-SMC) accurately controls the high-speed and precise linear motor drive movements through commands from the NC unit. The SL600G also features energy-saving designs and technologies that can reduce average energy consumption by up to 60 percent over traditional Wire EDMs.

A fixed jet high speed automatic wire threader (AWT) system is used for submerged and non-submerged threading. Combining thermal wire cut for a straighter wire and a new water-jet function improves the reliability of the AWT system. The exclusive closed guides used on the SL600G, combined with the FJ AWT, increases productivity even more.

The 3-sided rise/fall worktank provides large set-up space and ergonomic accessibility. The SL600G requires less operating space because three sides slide down. A no-drip feature keeps the shop floor clean and safe. The fluid level automatically adjusts according to workpiece thickness. The operator can check machining progress even on thin workpieces by stopping the slide tank in intermediate positions while machining.  The stainless steel tank interior allows quick maintenance.

Another machine tool on display during the event was the new TT1-400A, a high speed machining center designed for precision graphite and electrode machining that uses a 40,000 rpm high torque high speed HSK-E25 spindle with a maximum tool diameter of .236 in (6 mm).

The new TT1-400A achieves accelerations of up to 1.2 G on X-, Y-, Z-axis travels of 15.75 in (400 mm), 9.84 in (250 mm), and 11.81 in (300 mm), with a table-to-spindle distance of 5.91 in to about 17.72 in (150 mm to about 450 mm) on a 16.54 in x 10.24 in (420 mm x 260 mm) table that can hold workpieces weighing up to 22.05 lb (10 kg). The rapid feed rate is 1,440 ipm (36 m/min).

The TT1-400A uses linear motors and linear scales to achieve positioning accuracy within 3μm (0.00012 in), full stroke repeatability within 3μm (0.00012 in) and circular cutting of 1.575 in diameter material at 400 ipm within 3μm (0.00012 in). THK linear motion guides are used for high radial load capacity, high speed capacity and rigidity, vibration and shock resistance, and high rotational accuracy.

Visitors at the event viewed live machining demonstrations, toured the facility, and attended vendor presentations from Erowa System Solutions, Hirschmann Engineering, Hitachi Metals, Esprit CAD/CAM Software, Delcam CAD/CAM Software and Poco Graphite. “We wanted our visitors to walk away and feel that they have learned something new, that they are now better informed on the innovative technologies and processes available to them, “ explained Isabel Florence, the marketing manager for Sodick.  “They had the opportunity to educate themselves about our new machines directly from our engineers.”

Sodick was established in 1976 and has sold over 55,000 EDMs worldwide for the production of dies and molds and other various applications, with over 30,000 linear motor EDM deliveries. The company has over 3,000 employees across the globe in six ISO-certified manufacturing facilities, with technical centers located in Chicago, New Jersey and California

Sodick, Inc., 1605 North Penny Lane, Schaumburg, IL 60173, 847-310-9000, [email protected], www.sodick.com.