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Reducing Energy Usage with Wire EDM
pressure system. The filter pump runs all the time and the main pump
runs at the same speed whether it is cutting or sitting idle—so the
fluid is constantly circulating to maintain thermal stability. This
becomes a significant drain on energy. Today’s machines are more
environmentally and friendly—having evolved in many areas to
dramatically reduce their energy footprint. Digital anti-electrolysis
generators do a better job of shaping the cutting pulse and reducing the
ions generated in the water; this reduces the load on the DI resin
system—allowing it to last up to three times longer. Some systems use a
power regeneration circuit, which stores the over-current to create the
next ignition pulse. This eliminates the bank of resistors found on the
old DC generator—and the heat they produce—for decreased energy usage.
New fluid systems have more pumps that are designed specifically for
various functions, and therefore run less often. The main pump is now an
inverter-type unit that changes speed to control water volume and
pressure and only pushes water to the cutting heads when the machine is
running. Separate, smaller pumps now manage the fluid circulation
system—running water through the chiller and the machine to maintain
thermal stability at a much lower cost. The machine can also operate in a
cost save mode that reduces wire consumption and puts the machine to
sleep after the job is complete; in this sleep mode, the energy usage is
equal to that of a 100-watt light bulb.