Network-independent filling machine for liquids

Abstract

The network-independent filling machine (1) is intended for liquids which fill a container or storage tank (21). In particular, it is suitable for filling a tank for a cooling emulsion. It consists of a diaphragm valve, a control unit having a battery or accumulator, an inclination sensor in a float (15) for the level (26) and an on / off switch, it being possible for a signal to be triggered by the sensor when a predeterminable level (26) is reached in the switched-on state of the filling machine (1). The diaphragm valve in the housing of the filling machine (1) can be activated by the signal such that the diaphragm thereof can be closed by means of a solenoid. By means of an on / off switch, the filling machine (1) can be transferred back into its open initial state after the diaphragm valve has been closed.

Description

True Idea GmbH Badenerstrasse 808 8048 Zurich Cordless filling machine for liquids

[0001] The tools and workpieces of CNC machines, or more generally, machine tools for machining operations, are cooled during operation with a continuously supplied cooling emulsion. This emulsion is a mixture of water and a small amount of oil. A water line runs through a jet pump, which acts as an emulsion mixer. The pump draws a small amount of oil from an oil reservoir, mixes it with the water jet, and transfers it to a storage tank with a capacity of up to 10,000 liters or more for the cooling emulsion. From there, the cooling emulsion is drawn to supply the machine.

[0002] The size of storage tanks for these cooling emulsions in the machine industry varies considerably and depends on the type and number of machines to be supplied and the production capacity. Tank sizes typically fall within the following ranges: For smaller machine tools (e.g., CNC milling machines or lathes), tanks with a volume of approximately 50 to 200 liters are frequently used. These are sufficient for machines with low to medium utilization. In medium-sized production facilities or for machines with higher demands, tank sizes often range between 200 and 1,000 liters. These tanks offer sufficient capacity for extended operating times without constant refilling. In large manufacturing plants or for heavily used machines, storage tanks can hold 1,000 to 5,000 liters or more.Such tanks are necessary to ensure a continuous supply, especially for multiple machines connected to a central cooling emulsion supply. In large workshops or factories where numerous machines require cooling emulsions, central systems are used where the tanks often have a capacity of 10,000 liters or more.

[0003] To fill the coolant tanks, water is supplied via a hose. For larger tanks, this process takes so long that the person responsible lets the water run and only stops the flow once the desired fill level is reached. If they forget to do this, as can happen with the sporadic filling of coolant tanks in CNC machines, the resulting overflow can cause damage. In the worst-case scenario, this can amount to five- or six-figure sums in CHF, for example, if a workshop is flooded with a few millimeters or even centimeters of coolant, as has already occurred.

[0004] There are, however, automatic filling systems for coolant tanks. These are stationary and permanently installed. Therefore, a filling system with its own associated oil drum must be purchased for each machine, and a permanent water connection must be installed. Since this is expensive to purchase and complex to implement, a mobile filling unit is usually used. This unit consists of a wheeled oil drum with an emulsion mixer, which is supplied with water via a hose. However, this system lacks monitoring of the water level and the ability to stop the flow of liquid when the tank is full.

[0005] It is therefore the object of the present invention to create a mains-independent filling machine for liquids that can be used at any water supply to a container or tank, and in particular can also be retrofitted with minimal effort upstream of an emulsion mixer for filling a cooling emulsion tank.

[0006] This task is solved by a mains-independent filling machine for liquids for the supply line of a liquid to a container or tank, consisting of a diaphragm valve, a control unit with battery or accumulator, as well as a level sensor and an on / off switch for activating or deactivating the filling machine, wherein, when the filling machine is switched on, a signal can be triggered to the control unit when a predefinable level is reached by means of a sensor, so that the diaphragm valve can be closed by means of a solenoid, and when the on / off switch is activated, the filling machine can be returned to its initial state with the diaphragm valve closed.

[0007] Such a mains-independent filling system prevents coolant tanks from overflowing during filling in a highly simple and reliable manner. It can generally be used wherever a container or tank is filled via a conventional water connection and no mains power is available to monitor the level and shut off the water supply.

[0008] The following description uses figures to introduce this mains-independent filling machine in more detail, describing its components and explaining its function.

[0009] It shows: Figure 1: The filling machine in use, with an oil drum and a Cooling emulsion tank; Figure 2: The housing of the filling machine shown in an upright position in perspective; Figure 3: The housing of the filling machine shown in a horizontal position in perspective; Figure 4: The housing of the filling machine with its internal parts in a Exploded view; Figure 5: A float for installation in the storage tank; Figure 6: The internal parts of the swimmer.

[0010] Figure 1 shows the filling machine 1 in operation. Below the device, an oil drum 20 is visible, and to its left, a storage tank 21 for the ready-mixed cooling emulsion 22. The storage tank 21 is filled with an oil-water mixture, the water being supplied via line 23 from a standard water connection using a hose. The water passes through the filling machine 1, inside of which a diaphragm valve can stop or release the flow. After the filling machine 1, the water flows through an emulsion mixer 3, which acts as a jet pump. This pump draws oil from the oil drum 20 via the riser line 24 and mixes it with the water. The mixture exits the emulsion mixer 3 and finally enters the storage tank 21 via hose 25.

[0011] In this storage tank 21, the current water level 26 is shown, which should reliably never reach the upper rim 27 of the tank. The rise in the water level 26 is registered by a float 15, which contains a tilt sensor. This tilt sensor is connected by a twin-core cable 28 to a control unit inside the filling station 1. As soon as the float 15 tilts due to the rising water level, the tilt sensor interrupts the current flow in the twin-core cable 28, causing the control unit to close the diaphragm valve in the filling station 1 and thus interrupt the water supply.

[0012] Figure 2 shows the housing 2 of the filling machine 1 separately and in an upright perspective view. This housing 2 is only slightly larger than a cigarette pack, and all necessary components except the float are housed within it. A piezoelectric push button 10 is mounted on top of the housing 2 as an on / off switch. The filling machine 1 is powered by a simple 6V lithium battery 9. An LED 29 can also be installed as an indicator, which shows the operating status of the filling machine 1. For example, this LED lights up green when the filling machine 1 is in monitoring mode, i.e., actively monitoring the water level and interrupting the water supply when the level is reached. The LED 29 lights up red when the water supply is stopped and interrupted. A new monitoring cycle can be started by pressing the on / off switch 10. The diaphragm valve then opens, and the LED 29 switches to green.Regarding the service life of the 6V lithium battery 9, it can be noted that a similar battery operating the same diaphragm valve with 100 cycles per day can last up to 4 years. However, in this case, there will be far fewer cycles, so it can be assumed that this 6V lithium battery 9 will reliably power this filling machine for several years. Should the battery voltage eventually drop below an adjustable value, this can be indicated by a red flashing LED on the control unit 7. Then it is time to replace the battery. The filling machine can be started or stopped by pressing the piezo button or the on / off switch 10. The cylinder 13 protruding laterally from the housing 2 indicates a threaded fitting with an external thread for attaching a water hose fitting to connect the supply line 23 to a water supply.On the back of housing 2 there is an identical threaded fitting for connection to the emulsion mixer 3.

[0013] Figure 3 shows the housing 2 of the filling machine 1 in a horizontal position, shown in perspective. The housing base 11 is visible here. The housing 2 is therefore open at the bottom, and all components can be inserted from this lower side. The housing 2 is then screwed to this housing base 11, or the housing base 11 can be clicked into place on the housing 2 using click connections.

[0014] Figure 4 shows an exploded view of the housing of the filling machine 1 with its internal functional parts. At the top, the piezoelectric switch 10, which serves as an on / off switch, is inserted into the upper side of the housing 2 from above. Below the housing 2, a standard cylindrical diaphragm valve 5 is shown. This valve operates with a solenoid, which opens or closes the diaphragm of the diaphragm valve 5 via a voltage pulse. This allows the water supply to be interrupted or reactivated. The diaphragm valve 5 is housed in the valve housing 6, which is inserted into the housing 2 from below. The housing 2 has the recesses 12 with semicircular ends shown for this purpose. The valve housing 6 has a connection port 13, 14 at the front and rear, each with an external thread, for connecting a fitting of a water hose that supplies water from a standard water connection.The diaphragm valve 5 is controlled by a control unit 7, which receives an external signal when it is to close the diaphragm valve 5 and thus stop the water flow. This signal is interpreted as a current interruption in the circuit to the tilt sensor and back. As soon as such a current interruption occurs, it is registered at the control unit 7 via the sensor socket 8 and its cable, and the control unit then triggers the closing of the diaphragm valve 5. The sensor socket 8 is held inside the housing 2 by the socket terminal 4. All these components are inserted into the housing 2 from below. Finally, the battery 9 for the power supply of the control unit 7 is inserted into the housing 2 from below and then secured with the battery holder 30, which is inserted laterally near the lower edge of the housing. The housing 2 is then closed with the housing base 1.

[0015] A suitable bistable diaphragm valve 5 is one designed for pressures from 0.3 to 10 bar and battery-operated. This allows for a very compact design of the filling machine without an additional mains power connection. To the The inlet and outlet connections are directly attached to the valve housing 6. The control unit 7 regulates the diaphragm valve 5 based on the absence of a signal from the tilt sensor 18 in the float 15 and can be activated or deactivated using the piezo button as an on / off switch 10. Thus, when the storage tank reaches the fill level set by the float, the diaphragm valve 5 closes and can only be reactivated by pressing the on / off switch 10 or the piezo button. The entire system is powered by a simple 6V lithium battery 9.

[0016] The sensor of the filling machine, which monitors the water level 26 in the storage tank 21, will now be described. Figure 5 shows a possible example of such a sensor, here in the form of a pear-shaped float 15 made of, for example, PET or rubber, with an integrated tilt sensor 18. The float 15 can be sealed watertight with a silicone plug 16. Inside, the float 15 and the plug 16 contain a support 17 for inserting the tilt sensor 18. A two-core cable 28 is routed from the tilt sensor 18 through the plug 16 to the rear and leads to the housing 2 of the filling machine 1. As soon as the tilt sensor 18 interrupts the circuit, the control unit 7 actuates the diaphragm valve 5, which then shuts off the water supply.When the water level 26 in the storage tank 21 is low, the pear-shaped float 15 hangs vertically from its electrical cable 28, as shown in Figure 1. The cable is guided by a clamping bracket 19 or a magnetically attached holder. In both cases, the height of the float 15 can be easily adjusted or changed. As long as the float 15 is in an upright position, the tilt sensor 18 keeps the circuit closed. As soon as the water level 26 rises and reaches the float 15 and continues to rise, the float 15 is lifted by buoyancy and tilts to the side due to its pear shape. The tilt sensor 18 registers this tilt and thus interrupts the circuit in the two-wire cable 28, which is led via the connector 8 to the control unit 7 in the housing 2 of the filling machine 1. The interruption of the current is registered by the control unit 7, which then closes the diaphragm valve 5.

[0017] Instead of a float 15, there are many other ways in which the rising water level can be converted into an electrical signal and sent to the control unit of the filling machine 1. There are also various versions of Float switches, not just the one presented here with a pear-shaped float, are one option. A hydrostatic pressure sensor, for example, also offers a possibility. This measures the pressure exerted by the water on the sensor. Since the pressure is proportional to the height of the water column, the water level can be precisely determined in this way. Alternatively, ultrasonic sensors measure the distance between the sensor and the water surface based on ultrasound and its reflection at the water level. The time it takes for the sound to be reflected from the surface provides information about the water level. Ultrasonic sensors are particularly suitable for open water reservoirs. Capacitive level sensors, another option, measure changes in the capacitance between the probe and the water. They are non-contact and are often used in water tanks to enable continuous level measurements.Radar-based sensors function similarly to ultrasonic sensors, using radar-based electromagnetic waves to measure water levels. They offer high precision and perform well in extreme environments, such as with wastewater. Conductive sensors measure the electrical conductivity of the water to determine the level. They are particularly suitable for liquids with good electrical conductivity and are frequently used in industrial applications. However, for the present application, a float switch 15 with a tilt sensor 18 appears to be the simplest and most cost-effective option.

[0018] Instead of an electrical twin-core cable 28, which reports a power interruption at the tilt sensor 18 to the control unit of the filling machine 1, a wireless signal transmission to the control unit 7 can also be used. In this case, a transmitter unit must be present on the sensor side, and a corresponding receiver must be located in the housing 2 of the filling machine 1 at the control unit 7, which receives the signal so that the control unit 7 can process it.

[0019] Thanks to its very compact design and the fact that it does not require a mains power supply, this filling unit 1 can be connected directly to a water supply upstream of the emulsion mixer 3, i.e., between the supply line 23 and the emulsion mixer 3, for feeding the finished cooling emulsion into the storage tank 21. The desired fill quantity can be set by simply suspending the corresponding float switch in the storage tank 21, i.e., for example, a pear-shaped float 15 with an integrated tilt sensor 18, depending on the height at which the float 15 is suspended. When the desired fill level is reached, the float switch tips and the water supply is interrupted by the diaphragm valve 5. To further increase safety, a maximum filling time can be set on the control unit 7, which includes a timer function. This time period can then be monitored by the control unit 7, which sends a stop signal to the diaphragm valve 5 once the maximum set time period has elapsed.

[0020] It is clear that this filling machine 1 can be used for any supply of liquid into a container or tank, whether with or without an emulsion mixer. Number index 1 filling machine 2 cases 3 emulsion mixers 4 socket terminals 5 Diaphragm valve 6 Valve housings 7 Control unit 8 Sensor socket 9 Battery 10 on / off switches, piezo buttons 11 Case bottom 12 recesses with semicircular ends in the housing 2 13 Inlet ports on the valve housing 6 14 Drain ports on the valve housing 6 15 swimmers 16 sealing plugs for floats 15 17 Support part for tilt sensor 18 tilt sensor 19 Float holder 15 20 oil barrels 21 storage containers for cooling emulsion 22 Cooling emulsion 23 Water supply line Suction line for oil from the oil drum; hose from the emulsion mixer to the storage tank; level indicator at the top of the storage tank; signal cable for tilt sensor; LED on the housing; 2 battery holders

Claims

Patent claims 1. Mains-independent filling machine (1 ) for liquids for the supply line (23) to a storage tank (21 ), consisting of a diaphragm valve (5 ), a control unit (7) with battery (9 ) or accumulator, as well as a level sensor (18 ) and an on / off switch (10 ) for activating or deactivating the filling machine (1 ), wherein, when the filling machine (1 ) is switched on, the level sensor (18 ) can trigger a signal to the control unit (7) when a predefinable level (26) is reached, so that the diaphragm valve (5 ) can be closed by means of the same, and by pressing the on / off switch (10 ) the filling machine (1 ) can be returned to its initial state with the diaphragm valve (5) closed.

2. Mains-independent filling machine (1) according to claim 1, characterized in that the storage tank (21) is intended for a cooling emulsion and the filling machine (1) can be installed in the supply line to an emulsion mixer (3), which forms a jet pump for drawing oil from an oil container (20), and the level sensor (18) for the level (26) is a float (15) suspended from an electrical twin-core cable (28) with an inclination sensor (18) therein, such that when the level rises and the float (15) is inclined, a current interruption can be triggered by means of the inclination sensor (18) and transmitted as a signal to the control unit (7), so that the latter closes the diaphragm valve (5) and thus interrupts the water supply.

3. Mains-independent filling machine (1) according to claim 1, characterized in that the storage tank (21) is intended for a cooling emulsion and the filling machine (1) can be installed in the supply line to an emulsion mixer (3), which forms a jet pump for drawing oil from an oil container (20), and the sensor (18) for the level is a float (15) made of PET with a hanging pear shape and a sealing stopper (16) that can be tightly closed by means of silicone, suspended from an electrical twin-core cable (28), and the float (15) The tilt sensor (18) is included so that, when the water level rises and the float (15) tilts accordingly, a current interruption can be triggered by means of the tilt sensor (18) and transmitted as a signal to the control unit (7), so that it closes the diaphragm valve (5) and thus interrupts the water supply.

4. Mains-independent filling machine (1 ) according to one of the preceding claims, characterized in that it includes a housing (2) in which all components outside the float (15) with level sensor (18) are housed, namely the diaphragm valve (5) and its diaphragm valve housing (6) with two opposing connection ports (13, 14) for water supply and discharge in the form of fittings with external threads, which project laterally beyond the housing (2) in recesses (12), as well as the control unit (7) and the signal socket (8), as well as the battery or accumulator (9), and this housing (2) can be closed by a housing base (1 1 ).

5. Mains-independent filling machine (1 ) according to one of the preceding claims, characterized in that the electrical twin-strand cable (28) for the hanging float (15) and the level sensor (18) therein can be attached to a mechanical holder (19) on the storage tank (21 ), wherein the length of the hanging electrical cable (28) is adjustable at a clamp on the holder (19).

6. Mains-independent filling machine (1 ) according to one of claims 1 to 4, characterized in that the electrical signal cable (28) for the hanging float (15) with level sensor (18) can be attached to a magnetic holder (19) on the storage tank (21 ), wherein the length of the hanging electrical cable (28) is adjustable at a clamp on the magnetic holder or by positioning the magnetic holder.

7. Mains-independent filling machine (1 ) according to claim 1 , characterized in that the level sensor (18) is connected to a transmitter unit by means of which a signal from the level sensor (18) can be wirelessly transmitted to a receiver unit in the housing (2) of the filling machine (1 ) for processing by the control unit (7).

8. Mains-independent filling machine (1 ) according to one of the preceding claims, characterized in that the maximum filling duration can be set on the control unit (7) with a time element integrated therein, so that after the set time period has elapsed a stop signal to the diaphragm valve (5) and the latter is closed.

9. Mains-independent filling machine (1 ) according to one of the preceding claims, characterized in that it has an LED (29) as an indicator, to indicate the operating status, whether the solenoid valve (5) is closed or open, and to indicate an insufficient battery voltage by flashing.

10. Mains-independent filling machine (1 ) according to claim 1 , characterized in that one of the following sensor types is used as the level sensor (18) for monitoring the level (26): • A hydrostatic pressure sensor • An ultrasonic sensor • A capacitive level sensor • A radar-based sensor • A conductive sensor

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