Controller Coolant Deterioration Rate Monitoring
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Solution Overview
Problem
Existing coolant monitoring systems rely heavily on worker experience to determine coolant deterioration, leading to inaccurate and variable assessments of coolant performance, especially when reusable coolants are affected by viable bacteria and impurities, which can result in inconsistent machining quality.
Innovation Solution
A controller that records measurement history values and calculates the rate of change in coolant properties such as concentration, pH, and others, allowing for more accurate determination of coolant state and performance by incorporating both measurement values and their rate of change, enabling automated adjustments and operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional coolant monitoring using only measurement values (concentration, pH) is used, then the system is simple to operate, but the determination of coolant deterioration is inaccurate and varies by worker experience
Solution Approach 1:
The system pre-calculates and stores deterioration rates based on historical measurement data before actual coolant deterioration occurs. By accumulating measurement history and computing deterioration rates in advance, the system prepares accurate deterioration assessments that can be immediately applied when needed, eliminating the need for worker experience-based judgments.
Solution Approach 2:
The system continuously monitors coolant measurement values, calculates deterioration rates based on historical data, and uses this feedback to dynamically adjust machining conditions. The feedback loop compares current deterioration rates against thresholds and automatically modifies machining parameters, replacing subjective worker experience with objective, data-driven control.
2Reliability
If worker experience is used to determine coolant deterioration, then the system requires minimal equipment, but the determination accuracy varies and cannot be consistently reproduced
Solution Approach 1:
The system performs self-assessment of coolant deterioration by automatically calculating deterioration rates from its own historical measurement data. The controller autonomously determines coolant state without requiring external worker intervention or experience, ensuring consistent and reproducible assessments across different operators and time periods.
Solution Approach 2:
The system replaces the mechanical aspect of worker experience and manual judgment with an automated computational system. By substituting human decision-making with algorithm-based deterioration rate calculations, the system achieves consistent, reproducible, and objective coolant state determination that eliminates variability between different workers.
3Loss of information
If only current measurement values are used to monitor coolant, then the response time is fast, but the system cannot detect accelerating deterioration trends
Solution Approach 1:
The system pre-calculates deterioration rates by analyzing historical measurement data in advance, so that when current measurements are taken, the full trend information is already processed and available. This preliminary processing of historical data eliminates the need for time-consuming real-time trend analysis while preserving complete deterioration trend information.
Solution Approach 2:
The system continuously accumulates measurement history and maintains ongoing deterioration rate calculations, ensuring that trend information is continuously updated and available. This continuous data collection and processing maintains uninterrupted monitoring of deterioration trends without significant time loss, as the system is always ready with current trend assessments.
Data Source
AI summary
A controller for controlling a machine includes a coolant monitoring function. The controller generates and records history information in which the measurement values of a state of a coolant are associated with time information on the time when the measurement values are measured. Then, a rate of change in a measurement value for a state of the coolant is calculated based on the recorded history information, and a state of the coolant and a countermeasure therefore are determined based on the calculated rate of change in the measurement value.