During inspection of a used Robofil machine everything can look perfect: stable operation, wire not breaking, acceptable quality. The problem is that very often this is not the machine's natural state — it is the result of carefully chosen settings. To someone who does not know the process, everything looks correct. To an experienced operator, it is a clear signal that something is wrong.

🤔 Why Does Parameter Manipulation Work as Concealment?

The EDM process can be regulated across a wide range. This means you can increase productivity — but you can also restrict it to achieve stability. If a machine has a problem, the easiest thing is to reduce process load. Result: fewer errors, more stable operation, but significantly lower productivity and hidden technical problems.

🔴 Most Commonly Changed Parameters

1. Reduced Process Intensity

Lowering discharge energy and cutting aggressiveness makes the machine run more quietly, the wire breaks less often and problems are less visible. But: the process becomes very slow and does not show the machine's real capabilities at normal production settings.

2. Reduced Cutting Speed

The machine runs slower but more stably. Looks good in the demo — in production it is uneconomical and does not meet time requirements.

3. Demo Only in Safe Range

The machine is shown only with simple parts, specific settings and safe conditions — hiding problems that appear with more demanding production.

4. Stability at the Cost of Quality or Speed

Parameters set for a stable process — but at the cost of surface quality or productivity. No problems during the test, poor efficiency in practice.

🔍 How to Recognise These Actions?

  • Machine runs "too quietly" — if everything is very slow and stable: parameters may be deliberately lowered
  • No response to increased settings — ask to increase productivity; if problems appear the machine is operating at its limit
  • Low productivity with good stability — classic symptom of a "calmed" process
  • Limited demonstration scope — if you cannot change parameters or test more demanding parts: warning sign
⚠️ Key point: Parameters can hide symptoms but do not fix the cause. The machine may look fine during the test — but the problem still exists and will reveal itself in production.

✅ How to Protect Yourself?

  • Test different settings — not just the "standard" ones shown by the seller
  • Ask for higher productivity to be demonstrated and observe the machine's response
  • Do not evaluate the machine based on a single short test
  • If in doubt — ask for a longer observation period or a test on your typical part