Coolant Tank Sedimentation Layout for Fine Sludge Removal
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Solution Overview
Problem
Existing coolant processing apparatuses struggle to effectively remove fine sludge from coolants due to its small size, which often remains in the coolant and accumulates in the tank, leading to increased cleaning loads and potential damage to machine tools.
Innovation Solution
A coolant processing apparatus is designed with a first reservoir to retain sludge and a second reservoir for supernatant coolant, utilizing a boundary wall to separate the two, allowing sludge to precipitate and accumulate in the first reservoir while only the supernatant flows out, without the need for filters, and incorporating a sludge collection pump for efficient removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a filter is used to remove sludge from coolant, then larger particles can be removed, but fine sludge (less than 400 micrometers) cannot be sufficiently removed
Solution Approach 1:
The invention changes the removal mechanism from filtration (size-based blocking) to sedimentation (density-based separation). By allowing coolant to stand still in the reservoir, sludge particles settle to the bottom according to their density, enabling removal of fine particles without complex filtration structures.
Solution Approach 2:
The coolant tank is divided into two functional zones: a reservoir portion where sludge accumulates through sedimentation, and a storage portion that holds the cleaned coolant. This segmentation allows different removal mechanisms to operate in different zones, effectively handling both large and fine particles.
2Productivity
If coolant flows continuously through the tank, then processing efficiency is maintained, but sludge accumulates in the tank
Solution Approach 1:
The system performs preliminary sedimentation action by providing a reservoir where coolant stands still before being transferred to the storage portion. This preliminary action removes sludge proactively, preventing accumulation in the main tank while maintaining continuous circulation.
Solution Approach 2:
The invention extracts the sludge removal function from the main coolant circulation system by creating a separate reservoir portion dedicated to sedimentation. This extracted function handles sludge accumulation independently, allowing the main system to maintain continuous flow without contamination.
3Reliability
If the boundary wall height is increased to prevent sludge overflow, then sludge containment improves, but supernatant coolant flow is restricted
Solution Approach 1:
The boundary wall creates a local separation where the reservoir portion is confined for sedimentation, while the storage portion maintains open flow. The wall's height is optimized to provide sufficient containment for sludge while allowing adequate space for supernatant coolant to flow over the wall into the storage portion.
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 effectively removes fine sludge without filters, reduces cleaning loads, and prevents sludge accumulation in the coolant tank, enhancing the processing quality and extending machine tool lifespan.
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 remain; a second reservoir provided adjacent to the first reservoir and configured to retain therein the coolant flowing out from the first reservoir
Implementation Method 2
The sludge is, however, very fine and small and may not be sufficiently removed by the filter. The prior art configurations may suppress accumulation of sludge, but there is still a room for improvement in terms of effective removal of sludge.
Data Source
AI summary
A coolant processing apparatus removes sludge from a coolant discharged from a machine tool. The coolant processing apparatus includes a first reservoir and a second reservoir provided in a tank for retaining the coolant. The first reservoir includes a flow path in which the discharged coolant flows, and a portion downstream of the flow path to retain the coolant such that the sludge remains in the first reservoir. The flow path has at least one bend to bend a flow of the coolant at least once in a horizontal direction. The second reservoir retains the coolant flowing out from the first reservoir. A boundary wall is provided between the first and second reservoirs, at a location downstream of the at least one bend of the flow path, and has such a height that allows a supernatant of the coolant in the first reservoir to flow into the second reservoir.