A GA-based fuzzy logic controller for retrofitted wire transport system of wire-EDM

Wire tension as well as wire feed should be controlled tightly for the geometry and corner accuracy or wire-EDM. In this paper, a closed-loop wire tension control system for micro-wire-EDM is presented to guarantee a smooth wire transport and a constant tension value. In order to keep smooth wire transportation and avoid wire breakage during wire feeding, the reel roller is modified and the clip reel is removed from the wire transport mechanism. A genetic algorithm based fuzzy logic controller is proposed to investigate the dynamic performance of the closed-loop wire tension control system. Experimental results demonstrate that the developed wire transport system can result in satisfactory transient response, steady state response and robustness. The proposed genetic algorithm based fuzzy logic controller can obtain fast transient response and small steady-state error than a PI controller.