Method and apparatus for testing electrodes in an EDM process

An electrode discharge machine apparatus comprising:

• a servomechanism having a tool holder for mounting an electrode;
• an electrode loader for mounting an electrode in the tool holder;
• a workpiece area for supporting a workpiece to be machined;
• said servomechanism being movable from said electrode loader to said workpiece area;
• and
• a sensor for receiving therein an electrode mounted in the tool holder to test the electrode for conformance to predetermined tolerances.

An electrode discharge machining (EDM) machining method with an EDM apparatus of the type having a tool holder for mounting an electrode, an electrode loader with a supply of electrodes, and a workpiece mounting area for mounting the workpiece to be machined, the method comprising the steps of:

• moving the tool holder to the electrode loader;
• mounting an electrode having at least one tooth into the tool holder;
• moving the tool holder away from the electrode loader;
• providing a sensor module having a recess configuration of conductive material complementary to the electrode such that contact of the electrode with the conductive material when the electrode is inserted into the recess configuration of the sensor modules indicates that the electrode is out-of-tolerance or misaligned in the tool holder;
• inserting the electrode into the sensor module;
• determining if the electrode is in contact with the conductive material of the recess;
• moving the tool holder to the workpiece area;
• and
• machining the workpiece.

An electrode discharge machining (EDM) machining method with an EDM apparatus of the type having a tool holder for mounting an electrode, an electrode loader with a supply of electrodes, a sensor module with a recess configuration of conductive material complementary to the electrode such that contact of the electrode with the conductive material when the electrode is inserted into the sensor module recess configuration indicates that the electrode is out-of-tolerance or misaligned in the tool holder, and a workpiece mounting area for mounting the workpiece to be machined, the method comprising the steps of:

• moving the tool holder to the electrode loader;
• mounting an electrode having at least one tooth into the tool holder;
• moving the tool holder away from the electrode loader;
• positioning relatively the electrode and sensor module such that the electrode is disposed in the recess configuration of the sensor module;
• determining whether the electrode is in contact with the conductive material;
• moving the tool holder to the workpiece area;
• and
• machining the workpiece.

An electrode discharge machine apparatus comprising:

• a servomechanism having a tool holder for mounting an electrode;
• an electrode loader for mounting, an electrode in the tool holder;
• a workpiece area for supporting a workpiece to be machined;
• said servomechanism being movable from said electrode loader to said workpiece area;
• and
• a sensor for testing an electrode mounted in the tool holder for conformance to predetermined tolerances, said sensor including a sensor module with a recess configuration of conductive material complementary to an electrode such that contact of the electrode with the conductive material when the electrode is inserted into the sensor module recess configuration indicates that the electrode is out-of-tolerance or misaligned in the tool holder.