Central Coolant System with Dynamic Ratio Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Coolant filtration systems in metal working machines face issues with excessive oil content due to evaporation and improper replenishment, leading to increased costs, waste, and degradation of coolant performance, as well as reverse emulsion and reduced effectiveness in the cutting zone.
Innovation Solution
A central mix and makeup system that pre-treats water and oil mixtures, adjusts oil-to-water ratios, and reconditions return coolant to maintain optimal concentrations, incorporating features like de-ionization, reverse osmosis, particle filtration, ozone treatment, and recirculation to prevent oil-rich mixtures and ensure continuous coolant effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coolant is continuously replenished with fixed oil-to-water ratio, then coolant volume is maintained, but oil content exceeds desired range and performance degrades
Solution Approach 1:
The system uses sensors to continuously monitor the actual oil-to-water ratio in the coolant and automatically adjusts the replenishment rate and composition based on this feedback, preventing the ratio from exceeding the desired 6-10% oil range while maintaining adequate coolant volume
Solution Approach 2:
The system dynamically changes the parameters of replenishment coolant (oil concentration, flow rate) based on real-time conditions such as evaporation rate and current coolant composition, allowing adaptive maintenance of optimal oil-to-water ratio rather than using fixed composition replenishment
2Quantity of substance
If excessive oil is added to replenish evaporated coolant, then coolant volume is restored, but coefficient of drag increases and cutting zone performance degrades
Solution Approach 1:
The system monitors coolant composition and adjusts oil addition rates based on feedback signals, ensuring oil content remains within the optimal 6-10% range and preventing excessive oil accumulation that would increase drag and degrade cutting zone performance
Solution Approach 2:
The replenishment system transitions from static fixed-ratio mixing to dynamic adjustment of oil-to-water ratio based on real-time evaporation rates and coolant composition, allowing the system to adapt to changing conditions and maintain optimal performance characteristics
3Ease of operation
If central coolant system is implemented, then coolant distribution is improved, but system complexity increases
Solution Approach 1:
The central coolant system integrates multiple functions including mixing, storage, distribution, monitoring, and automatic replenishment into a single multi-functional platform, improving coolant distribution across multiple machines while managing complexity through functional integration rather than separate systems
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 effectively maintains optimal coolant composition, reducing waste and costs by continuously recalibrating the coolant mixture, preventing oil-rich conditions, and ensuring long-term coolant integrity and performance by adjusting oil-to-water ratios and removing residual solids and tramp oil.
Implementation Method 1
an inlet conduit including a branching location for feeding a portion of an untreated water supply to a de-ionization canister, a reverse osmosis system or other supply of low TDS water
Implementation Method 2
a mixing valve in communication with the inlet conduit recombining a remaining untreated portion of the water supply with the de-ionized portion
Implementation Method 3
a chiller in communication with the outlet of the filter and adjusting a temperature of the coolant
Implementation Method 4
introducing a plurality of ozone or oxygen particles within a submerged location of the main reservoir
Data Source
AI summary
A system for producing and supplying a coolant to a filtration sub-system, and for reconditioning and recombining a return flow of used coolant. A main reservoir is in two way communication with the filtration sub-system via a clean coolant outlet and a dirty coolant return. An inlet feeds an untreated water supply to a de-ionization canister. A mixing valve in communication with the inlet recombines a remaining untreated portion of the water supply with the de-ionized portion. A mixing pump intermixes the water supply with a chemical concentrate to produce a coolant delivered to a main reservoir. A volume of coolant is drawn through an outlet from the reservoir and communicates the coolant to a particle filter, a chiller, and prior to outputting to the filtration sub-systems. The used return coolant is filtered and reintroduced to the main reservoir.