Power Electronics-Driven Intelligent Adaptive Control System for Electrical Discharge Machining of Molybdenum-Titanium-Zirconium Alloy

In order to fully leverage the capabilities of adaptive electrical discharge machining (EDM) and address the conflict between machining stability and machining efficiency, a power electronics-driven intelligent adaptive EDM system is proposed. Based on “perceived” discharge pulse signals in the gap between the electrode and the workpiece, the system integrates power electronic parameter detection and computer-aided signal processing to compute machining environment and state indices through a “cognitive process”. A power electronics-optimized control framework is designed to define desired machining state expectations, balancing efficiency and stability via real-time adjustment of EDM power supply parameters and electrode servo dynamics. Two cascaded adaptive control loops are adopted: one for generating control behavior guidelines and the other for optimizing power electronic drive and servo control behavior. Experimental results indicate that the system significantly enhances machining capabilities, enabling stable and rapid machining of nuclear industry-grade molybdenum-titaniumzirconium alloys. Traditional electrical discharge machining cannot process this type of alloy. The integration of power electronic drive optimization and digital control technology promotes the development of EDM towards high-efficiency, low-energy-consumption electrical manufacturing, demonstrating profound implications for advancing electronic power and intelligent manufacturing technologies.