Automatic Coolant Mixer for Machine Tools
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Solution Overview
Problem
Machine tool operators face challenges in maintaining optimal coolant levels and concentrations in coolant storage tanks, leading to issues like accelerated oxidation of machine components and discoloration of finished parts, due to imbalanced coolant chemistry and inadequate maintenance practices.
Innovation Solution
An automatic coolant mixer system that includes a chassis, a concentrate tank, flow control valves, and a mixer, controlled by a control system to mix coolant concentrate with water based on specified concentrations and current tank levels, ensuring continuous and precise coolant replenishment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual coolant maintenance is performed, then operational flexibility is maintained, but coolant level and concentration consistency deteriorates
Solution Approach 1:
The system enables self-service operation where the coolant mixer automatically monitors coolant levels and concentrations, then replenishes and mixes coolant without operator intervention. Sensors detect coolant parameters and trigger automated mixing cycles, eliminating manual maintenance while ensuring consistent coolant quality.
Solution Approach 2:
The system incorporates feedback mechanisms where sensors continuously monitor coolant level and concentration in the tank. This data feeds back to the control system, which adjusts the mixing operation accordingly - adding concentrate or water as needed to maintain precise concentration targets, thereby ensuring consistency without manual intervention.
2Measurement precision
If automated coolant mixing is implemented, then coolant concentration precision is improved, but system complexity increases
Solution Approach 1:
The system replaces manual mechanical operations with electronic control and sensing. Instead of operators physically measuring and mixing coolant, electronic sensors measure concentration and level, and electronic valves control the mixing process, achieving higher precision while managing complexity through automation.
Solution Approach 2:
The control system performs multiple functions - monitoring coolant level, measuring concentration, calculating required mix ratios, controlling valve operations, and tracking maintenance schedules - all within a single integrated unit. This multi-functionality consolidates complexity into one system rather than distributing it across multiple separate components.
3Reliability
If frequent coolant monitoring is performed, then coolant quality is maintained, but operational time is reduced
Solution Approach 1:
The system implements continuous monitoring of coolant level and concentration through sensors that operate throughout machine operation. This continuous detection enables real-time adjustments without interrupting machining processes, maintaining coolant quality while eliminating the need for periodic manual checks that consume operational time.
Solution Approach 2:
The system performs preliminary mixing actions before coolant deficiencies become critical. By continuously monitoring and automatically replenishing coolant at predetermined thresholds, the system prevents chemistry degradation before it occurs, maintaining reliability without requiring reactive maintenance that would interrupt operations.
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 system automatically maintains optimal coolant levels and concentrations, reducing the risk of machine component damage and ensuring consistent machining performance by continuously monitoring and adjusting the coolant mixture according to operating parameters.
Implementation Method 1
a mixer configured to mix a concentrate with water
Data Source
AI summary
A machine tool coolant supply system includes a chassis configured to mount the coolant supply system to a coolant storage tank of a machine tool. The coolant supply system further includes a concentrate tank arranged within the chassis, a first flow control valve coupled to the concentrate tank, a second flow control valve coupled to a water supply line, and a mixer configured to mix a concentrate with water. The mixer includes a first inlet coupled to the first flow control valve and configured to receive the concentrate from the concentrate tank via the first flow control valve, a second inlet coupled to the second flow control valve and configured to receive the water from the water supply line via the second flow control valve, and an outlet configured to dispense a mixture of the concentrate and the water into the coolant storage tank of the machine tool. The coolant supply system further includes a control line arranged in electrical communication with the first flow control valve and the second flow control valve, wherein the control line is configured to communicate control signals from a machine tool control system to actuate the first flow control valve and the second flow control valve to control a ratio of the concentrate and the water supplied to the mixer.