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Intelligent EDM Cell for Aero-Engine Blade Profiled Slots

Customer Pain Points

Core Requirements: Targeting the EDM scenario of profiled slots on aero-engine blades, this project resolves the core pain points of traditional machining.
Existing Bottlenecks:
Under the traditional mode, blade clamping and positioning rely on manual labor, with insufficient accuracy directly undermining machining consistency.
Blade and electrode identity recognition and data transmission rely on manual recording—low efficiency and error-prone, making full-process traceability impossible.
Electrode replacement, dressing, and scrapping lack an automated mechanism, prone to quality defects caused by undetected wear.
Blade and electrode inbound/outbound and loading/unloading involve heavy manual intervention, with poor process handoffs, unable to meet the high-precision, high-efficiency machining demands of aviation parts—an integrated intelligent machining cell is urgently needed.

Core configuration of the line body

Core Machining Equipment: Two six-axis die-sinking EDM machines, precisely matching the EDM requirements of aero-engine blade profiled slots, ensuring machining accuracy and stability.
Automation Execution Unit: One six-joint robot paired with a CHINAF loading/unloading cart to achieve automatic blade and electrode loading/unloading and transfer; equipped with a high-precision pallet system to ensure accurate positioning.
Intelligent Warehousing Unit: CHINAF workpiece warehouse and electrode warehouse enable automatic inbound/outbound of blades and electrodes, reducing manual operation and achieving precise material control.
Inspection & Auxiliary System: CHINAF loading/unloading stations (integrating a workpiece and electrode prediction system) combined with an RFID automatic identification system realize identity recognition and automatic data transmission; equipped with an electrode dressing system, CHINAF cleaning system, and safety protection system to guarantee machining quality and cell safety.
Intelligent Control Hub: HF-PCS control system achieves cell-wide centralized control, building an integrated digital management system.

Core Value

Full-Process Automation, Improving Production Efficiency: Through the coordination of the six-joint robot and HF-PCS control system, full-process automated operation is achieved for blade and electrode loading/unloading, transfer, machining, and inbound/outbound; manual intervention reduced by over 80% and process-handoff efficiency raised by 50%, realizing unattended process control and greatly improving production efficiency.
High-Precision Control, Guaranteeing Machining Quality: The five-axis NC loading/inspection station integrates contact measurement and vision technology, controlling workpiece pose adjustment accuracy within ±0.005 mm; online real-time electrode-wear detection synchronously transmits repair parameters, with electrode-repair accuracy reaching 99.9%, ensuring the blade profiled-slot machining yield rate rises above 99.8%, meeting the high-precision requirements of aviation parts.
Significant Cost Optimization, Breaking the Technical Bottleneck: Innovatively adopting graphite electrodes and solving their machining difficulties, compared with traditional copper-tungsten electrodes, machining efficiency is more than tripled, electrode procurement and usage cost drops to about 25% of copper-tungsten electrodes, saving about ¥30,000 per batch, and long-term annual cost reduction can exceed 20%.
Digital Management, Achieving Full-Process Traceability: Integrating HF-PCS control system and RFID system realizes automatic collection, transmission, and management of blade and electrode identity information and machining data; automatic machining-parameter compensation response time ≤ 1 second, traceability rate reaching 100%, providing precise data support for process optimization and equipment maintenance, and helping the customer achieve lean management.