Page 45 - EDM Today Spring 2025
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SPRING 2025  Key Capabilities
 NEW  EDM Today Magazine                        EDM Today Magazine                            EDM Today Magazine
          1. Periodic Surface Measurement
            •  Employs non-contact “Feedback” sensors to sample the evolving workpiece geometry and surface profi le
 TECHNOLOGY      at fi xed intervals.

            •  Translates raw sensor data into industry-standard VDI surface class estimates, enabling direct comparison
              to the user’s target.

 EXERON INTRODUCES EXO-TECHNOLOGY   2. Adaptive Parameter Tuning
 THE NEXT GENERATION IN EDM PERFORMANCE    •  Utilizes closed-loop control algorithms to tweak spark energy and downtimes for real-time optimized
              gap control.

            •  Automatically calculates the optimum parameters and correction offsets between roughing, semi-fi nishing, and
              fi nishing operations with basic data input, ensuring optimal material removal rates and surface integrity.
 Revolutionizing EDM with Exoguide and Exogen:   EDM Today Magazine  EDM Today Magazine       EDM Today Magazine
 A Deep Dive into Exeron’s Exo-Technology  3. User-Friendly Interface and Data Logging

 As manufacturing pushes the limits of precision,     •  Provides a dashboard showing live comparisons of
 effi ciency, and adaptability, electrical discharge       actual vs. target surface class.
 machining (EDM) remains indispensable for creating
 complex geometries and ultra-fi ne surface fi nishes in     •  Records complete time stamped parameter
 hard, exotic materials. Yet despite its strengths,       histories, enabling post process analysis, traceability,
 EDM’s reputation for requiring seasoned experts—      and continuous refi nement of control strategies.
 and its susceptibility to process variability—have
 long constrained throughput and accessibility.   4. Skill Democratization
 With Exeron’s advanced Exogen generators and their
 latest Exo-Technology modules, you can tackle these     •  New operators select the desired fi nish (e.g., VDI 24)
              and launch the job. Exoguide’s embedded expertise
 challenges head-on, transforming EDM from a   EDM Today Magazine  EDM Today Magazine         EDM Today Magazine
 specialist’s craft into an accessible, data-driven process.      is engaged to help meet the desired outcome.
            •  Veteran specialists can refi ne or override settings,

              machine-learning pipeline.
 The State of Modern EDM:       feeding their insights into the module’s ongoing
 Opportunities and Obstacles  Exeron 316 CNC EDM
  Precision demands    TECHNICAL UNDERPINNINGS                   Technology Editor Screen – Part of Advanced HMI
 Industries such as aerospace, medical devices, and micro injection molding routinely demand surface fi nishes in the
 VDI 16–24 range or fi ner, with tolerances measured in microns. EDM excels here, but only when spark energy, pulse   •  Machine Learning Enhanced Models
 duration, and gap control are meticulously balanced.    Exoguide leverages regression models trained on millions of EDM cycles, correlating input parameters with fi nish
            outcomes across a range of electrode materials (copper, graphite, copper tungsten) and workpiece alloys.
  Skill bottlenecks  EDM Today Magazine         EDM Today Magazine                            EDM Today Magazine
 Traditional die sinking EDM relies on decades of “tribal knowledge.” Operators select static parameter sets at job   •  Control Theory Integration
 start, then monitor progress manually. Any real-time problems—due to electrode wear, dielectric contamination, or     Advanced Proportional-Integral-Derivative (PID) and model predictive control (MPC) schemes ensure stability,
 material inhomogeneities—can force rework or scrap.    avoiding overshooting key metrics like surface roughness (Ra) and dimensional tolerance.
  Throughput limitations  •  Scalable Architecture
 Without in-process feedback, shops must build in safety margins: longer cycle     Packaged as a “plug-and-play” software module, Exoguide expands the Exogen Generator and is architected to
 times, conservative spark settings, and repeated fi nishing passes, which slows     support future expansions (e.g., Complete Pulse manipulation, wear rate calculation, etc.) without hardware
          1. Fully Encapsulated, Compact Design EDM Today Magazine
 overall production and infl ates costs.   overhaul.
 Exeron’s response: modularize and automate the two core “black boxes” of   Exogen: A Next Generation Power Generator
 EDM—process control and power generation—into software upgradeable
 building blocks that continually learn, adapt, and integrate.  EDM Today Magazine            EDM Today Magazine
          While Exoguide masters the “brains” of the process, Exogen redefi nes its “heart”—the adaptive pulse generator that
          drives spark formation.
 Exoguide: More than AI, It is Intelligent Closed-Loop Process Control

 At its core, Exoguide is a real-time monitoring and control module that     FUNDAMENTAL INNOVATIONS
 continuously measures surface fi nish metrics and dynamically adjusts EDM
 parameters to achieve and maintain a specifi ed target. The result is superior
 surface fi nishing with reduced electrode wear.     •  The entire power electronics stack resides within a sealed, dust  and moisture-proof housing. External
   EDM Today Magazine                           EDM Today Magazine                            EDM Today Magazine
 Superior Surface Finish with       contamination risks—long a foe of generator reliability—are virtually eliminated.
 Low Electrode Wear                                                                            (Continued on next page)
 42  EDM Today, Spring 2025 Issue  EDM Today, Spring 2025 Issue                                                43
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