New Design

A new controller of EDM or pulse power regulator has been developed. The new design includes an accurate wave generator, a special method of current control and a gap voltage detection. With the innovation of the new design, On-time and Off-time can reach a minimum of 1µs or even less. Higher pulse frequency makes it possible to achieve higher standard of surface finish. Furthermore, the conventional resistors for current control are completely omitted, so the new generator can produce an extremely high electrical energy utilization ratio. As result, a lightweight Switching Power Supply can be used in the system instead of a regular heavy transformer. During any period of the discharging, the discharge voltage and current are exactly controlled. Therefore, it provides equal-energy discharge at any time point. This kind of power supply ensures high stability, high quality of the surface finish and high machining efficiency. The new EMD has much higher erosion rate while working under higher gap voltage. In addition, a protection circuit avoids short circuit between electrode and workpiece.

Here are some features of the system,

   1. No current-limiting resistors in series with the electrode.
   2. Continuously adjustable On-Time and Off-Time in range of 1 - 900µs.
   3. Continuously adjustable peak current in range of 1 - 60A.
   4. Equal-energy discharge control, high stability and efficiency.
   5. Stylish Extensible Modular Construction.
   6. Flexible interface to external peripheries.
   7. Suitable for both single axis and 3-axis machines.
   8. LCD display showing 12 machining parameters.
   9. Low cost and high performance.
   10. Core technique can be applied to other machines which use current-limiting resistors.

Comparision chart:

Features and Highlights	Conventional  Technique	New Design
Current-Limiting Resistors	Required	Removed
Current Adjustment	Stepwise	Continuously  (1A interval)
Adjustable On-Time & Off-Time	Stepwise	Continuously
Minimum On-Time & Off-Time	>10µs	250ns
Power Consumption (60A)	6KW	2.5KW
Flexible Peripheral Interface	No	Yes
Power Transformer	Required	Not Required

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