Cyclone Coolant Filtration for Sludge Clogging Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing technologies face challenges in accurately detecting the level of sludge in coolant containers, leading to difficulties in identifying abnormalities related to sludge accumulation.
Innovation Solution
A machine tool equipped with a cyclone filter that separates coolant into clean and contaminated streams using centrifugal force, featuring a diaphragm mechanism to control flow rate and a flow sensor to detect abnormalities, along with a collection mechanism for sludge removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a camera is used to detect sludge accumulation in the container, then the detection system is simple, but the detection accuracy is insufficient because sludge is suspended in coolant making height detection difficult
Solution Approach 1:
The patent replaces the optical detection system (camera) with a flow sensor that directly measures the flow rate of contaminated coolant. This substitution of detection method enables accurate measurement of sludge accumulation by monitoring flow rate changes caused by diaphragm clogging, resolving the contradiction between simple device structure and accurate measurement.
Solution Approach 2:
The patent introduces the flow rate as an intermediary parameter to indirectly detect sludge accumulation. Instead of directly measuring sludge height, the system measures the flow rate of contaminated coolant, which changes when sludge clogs the diaphragm. This intermediary measurement approach achieves accurate detection without requiring direct visual access to suspended sludge.
2Reliability
If the diaphragm mechanism restricts flow rate to enable detection, then abnormality detection becomes possible, but the system becomes more complex with additional components
Solution Approach 1:
The diaphragm mechanism serves multiple functions: it acts as a flow restriction element for detection purposes, serves as part of the cyclone filter structure, and functions as a clogging indicator. By making the diaphragm multi-functional, the system achieves reliable abnormality detection without adding separate dedicated detection components, thus resolving the contradiction between detection capability and system complexity.
3Loss of time
If sludge accumulates in the container, then the coolant needs to be replaced, but continuous operation and coolant reuse become difficult
Solution Approach 1:
The patent implements a feedback mechanism where the flow sensor continuously monitors the flow rate of contaminated coolant and provides real-time information about diaphragm clogging status. When the flow rate drops below a threshold, the control unit receives feedback and can trigger alerts or automatic responses, enabling timely intervention before complete clogging occurs. This feedback system ensures continuous operation by preventing total system failure and maintains coolant reuse capability through timely sludge removal decisions.
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
Enables accurate detection of sludge clogging and automatic sludge removal, ensuring continuous operation and reuse of coolant, thereby maintaining machining efficiency.
Implementation Method 1
a cyclone filter for separating the coolant supplied from the first reservoir portion into a clean coolant and a contaminated coolant using centrifugal force
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided is a new technology for detecting an abnormality related to sludge. A machine tool capable of machining a workpiece while ejecting a coolant includes a first reservoir portion for storing a coolant that contains sludge generated by machining the workpiece, a cyclone filter for separating the coolant supplied from the first reservoir portion into a clean coolant and a contaminated coolant using centrifugal force, and a control unit for controlling the machine tool. The cyclone filter includes: a first outflow tube for sending out the clean coolant; a second outflow tube for sending out the contaminated coolant; a diaphragm mechanism for restricting a flow rate of the contaminated coolant flowing through the second outflow tube; and a flow sensor for detecting the flow rate of the contaminated coolant flowing through the second outflow tube. The control unit executes predetermined abnormality handling processing based on the flow rate detected by the flow sensor being lower than a predetermined flow rate.