Atomizer With Segmented Lubricant Passages For Precision Metal Forming
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Solution Overview
Problem
Current sprayers for lubrication in metal forming processes are inefficient, resulting in excessive lubricant usage, environmental hazards, and inability to achieve low flow rates necessary for precise lubrication, leading to unsanitary conditions and health risks.
Innovation Solution
A sprayer design featuring a nozzle with a core and separate lubricant passage sections, combined with a ring and air knife passages to achieve a low flow rate and fine spray, utilizing an electrostatic field for precise lubricant distribution and incorporating a piezoelectric valve for flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional sprayers are used to lubricate metal sheets, then the metal sheets can be lubricated, but large quantities of lubricant are consumed and spray accuracy is poor
Solution Approach 1:
The spray device divides the lubricant flow into multiple separate passage sections (at least three sections) arranged around the spray axis. Each section delivers lubricant through a dedicated passage with dimensions of less than 0.5 mm, enabling precise control of lubricant distribution while reducing overall consumption through targeted application.
2Quantity of substance
If conventional sprayers operate at high flow rates, then sufficient lubricant is delivered to the part, but the spray cannot achieve very fine atomization and low flow rates
Solution Approach 1:
Each passage section has specifically optimized local dimensions (less than 0.5 mm radial dimension) and is equipped with dedicated air knives that create localized aerodynamic fields. This local optimization enables fine atomization in each section while the collective effect of multiple sections achieves the required total lubricant quantity.
3Reliability
If large quantities of lubricant are sprayed to ensure adequate lubrication, then the parts are sufficiently lubricated, but working conditions deteriorate with increased fire risk and unsanitary environments
Solution Approach 1:
The invention extracts and eliminates the harmful excess lubricant by implementing a precision delivery system that applies only the necessary amount. The multiple passage sections with controlled dimensions and air-assisted atomization ensure adequate lubrication effectiveness while reducing lubricant quantity by a factor of 5 or more, thereby eliminating fire risks and unsanitary working conditions.
4Ease of manufacture
If conventional sprayers are used, then lubrication can be applied, but cleaning and drying processes consume excessive solvent and energy
Solution Approach 1:
The invention converts the potential harm of excess lubricant application into benefit by implementing precise control mechanisms. The multiple passage sections with air knives create fine atomization that ensures uniform, adequate lubrication without excess, thereby eliminating the need for extensive cleaning and drying operations and reducing solvent and energy consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances spraying efficiency, reduces lubricant consumption, and improves precision, minimizing environmental impact and health risks while enabling low flow rates necessary for precise lubrication.
Implementation Method 1
a second passage for ejecting a first air knife, which is arranged around the first passage in a direction peripheral to the spray axis and which, in operation, gives the first air gap a helical direction
Implementation Method 2
An electrostatic field is created between the grounded part to be lubricated and the sprayer. This electrostatic field makes it possible to guide the particles of lubricant, themselves electrostatically charged, following the same polarity from the sprayer to the part
Data Source
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AI summary
This atomizer makes it possible to spray a lubricant product along a spraying axis (Z-Z) and comprises a first passage for the product which is centred on the spraying axis, a nozzle (2242) which is centred on the spraying axis (Z-Z), and a core (2250) which is disposed coaxially inside the nozzle. The atomizer also comprises a second passage (2248) for ejecting a first jet of air, which is arranged around the first passage in a peripheral direction with respect to the spraying axis (Z-Z) and which, in operation, confers a helical direction on the first jet of air. In addition, the first passage is defined between the core (2250) and the nozzle and is formed by a plurality of separate passage sections (2260).