Coolant Tank Reservoir Layout for Fine Sludge Separation
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Solution Overview
Problem
Existing coolant processing apparatuses are ineffective in removing fine sludge from coolants due to the sludge's small size, which often results in accumulation in the coolant tank, leading to increased cleaning loads and potential damage to machine tools.
Innovation Solution
A coolant processing apparatus with a first reservoir and a second reservoir separated by a boundary wall, where the sludge is retained in the first reservoir due to its settling nature, allowing only the supernatant coolant to flow into the second reservoir, effectively removing fine sludge without the need for filters, and utilizing a sludge collection pump to facilitate efficient removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a filter is used to remove sludge from coolant, then chips and large sludge can be removed, but fine sludge (less than 400 micrometers) cannot be sufficiently removed
Solution Approach 1:
The tank is divided into multiple reservoirs (first reservoir, second reservoir, third reservoir) separated by boundary walls at different heights. This segmentation allows different stages of sludge settling to occur in different zones, with the first reservoir capturing fine sludge through controlled flow conditions, the second reservoir handling intermediate settling, and the third reservoir collecting heavier deposits. This resolves the contradiction by achieving fine sludge removal without requiring complex filtration systems.
Solution Approach 2:
The boundary wall acts as an intermediary structure between reservoirs, creating a controlled interface that allows supernatant coolant to pass while retaining sludge. The specific height of the boundary wall (e.g., 100-500mm) creates a mediator zone where flow velocity is reduced and sludge can settle naturally, enabling fine sludge removal without mechanical filters.
2Manufacturing precision
If the boundary wall height is increased to retain more sludge, then sludge removal effectiveness improves, but the flow of supernatant coolant may be restricted
Solution Approach 1:
The boundary wall height is optimized to specific parameter ranges (100-500mm, or 1/10 to 1/3 of tank height) to balance sludge retention and coolant flow. This parameter optimization ensures that the wall is tall enough to create sufficient settling zone for fine sludge (improving removal effectiveness) but not so tall as to create excessive flow resistance (maintaining productivity). The multi-reservoir design further distributes the retention function, allowing each boundary wall to be of moderate height.
3Loss of substance
If conventional coolant processing methods are used, then chips can be removed, but fine sludge accumulates in the tank requiring frequent cleaning
Solution Approach 1:
The invention converts the harmful accumulation of fine sludge into a beneficial controlled settling process. By designing the tank with multiple reservoirs and appropriate boundary walls, the natural settling tendency of sludge (which would normally cause problems) is harnessed to separate fine sludge from coolant in the first reservoir. The sludge accumulates in a controlled manner in the first reservoir rather than throughout the entire tank, making removal easier and less frequent. This resolves the contradiction by reducing overall sludge accumulation in the usable coolant volume while minimizing cleaning requirements.
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
This configuration allows for the effective removal of fine sludge, reducing the cleaning load and preventing sludge accumulation in the coolant tank, thereby enhancing the processing quality and extending the lifespan of machine tools.
Implementation Method 1
a first reservoir provided inside of a tank for the coolant and configured to retain the coolant therein such as to cause the sludge to stay
Implementation Method 2
a boundary wall provided to configure a boundary between the first reservoir and the second reservoir and to have a height that allows a supernatant of the coolant retained in the first reservoir to flow out to the second reservoir
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
One object is to remove sludge from a coolant that is discharged from a machine tool and that includes the sludge. In a tank for the discharged coolant, a clean layer after removal of chips and relatively large sludge by means of a filter is further divided by partition plates 21 and 22 and a boundary wall 23 into a first reservoir on an upstream side of the boundary wall 23 and a second reservoir on a downstream side of the boundary wall 23. The coolant including fine sludge that is not removed by the firster is retained in the first reservoir, so that the sludge precipitates or stays in the coolant. The boundary wall 23 is configured to have a height that is lower than the heights of the partition plates 21 and 22 and thereby allows only a supernatant of the coolant that contains almost no sludge to flow out from the first reservoir to the second reservoir. This configuration enables the fine sludge to be effectively removed from the coolant.