Dielectric Fluid Processor Pump Frequency Pressure Mapping
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Solution Overview
Problem
The existing dielectric working fluid filtration systems require a pressure sensor to determine filter replacement timing, leading to increased costs.
Innovation Solution
A dielectric working fluid processor that uses an inverter to control the pump's rotation speed by varying the frequency of electric power, allowing the feed pressure of the dielectric working fluid to be obtained without a pressure sensor, using a map correlating electric power frequency and feed pressure to determine filter clogging and necessity for replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is used to detect feed pressure for determining filter replacement timing, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the mechanical pressure sensor with an electrical control system. The inverter controls the pump motor speed by adjusting power frequency, and the relationship between frequency and feed pressure is established through a map created during pump performance testing. This substitution eliminates the need for physical pressure sensors while maintaining measurement capability through electrical parameters.
Solution Approach 2:
The patent changes the measurement parameter from direct pressure detection to power frequency control. By creating a correlation map between pump power frequency and feed pressure during testing, the system can determine feed pressure conditions by monitoring the electrical frequency parameter instead of mechanical pressure, thereby simplifying the device structure.
2Reliability
If a pressure sensor is installed to monitor filter clogging, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive pressure sensing hardware with a control system that utilizes the existing inverter's frequency control capability. The feed pressure information is derived from the relationship between pump power frequency and pressure characteristics, eliminating the need for additional pressure sensors and reducing manufacturing costs while maintaining reliable filter replacement timing determination.
Solution Approach 2:
The system uses the inverter's inherent frequency control function to also provide feed pressure information. The same control unit that regulates pump speed also determines filter replacement timing by referencing the frequency-pressure map, making the system self-sufficient without requiring separate pressure sensing components.
3Ease of operation
If the pump rotation speed is controlled by varying electric power frequency, then ease of operation is improved, but device complexity increases due to inverter requirement
Solution Approach 1:
The patent makes the inverter serve multiple functions: it controls pump rotation speed for efficient operation and simultaneously provides feed pressure information for filter replacement determination. By creating a frequency-pressure correlation map, the same frequency control mechanism used for speed regulation also enables pressure monitoring, making the inverter a multi-functional component that reduces overall system complexity.
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 determination of feed pressure and filter replacement needs without a pressure sensor, reducing manufacturing costs and allowing for automated notification and decision-making regarding filter usability and replacement.
Implementation Method 1
an inverter configured to control electric power to be supplied to the pump; a pump controller configured to control a rotation speed of the pump by varying frequency of electric power supplied from the inverter to the pump
Data Source
AI summary
A dielectric working fluid processor for processing dielectric working fluid used in a wire electrical discharge machine includes: a dirty liquid tank for storing dielectric working fluid containing machining swarf; a filter for removing machining swarf from the dielectric working fluid in the dirty liquid tank; a clean liquid tank for storing the dielectric working fluid from which the machining swarf has been removed by the filter; a pump for supplying dielectric working fluid from the dirty liquid tank to the filter; an inverter for controlling electric power to be supplied to the pump; a pump controller for controlling the rotation speed of the pump by varying the frequency of electric power supplied from the inverter to the pump; and a feed pressure obtainer for obtaining the feed pressure of the dielectric working fluid supplied from the pump to the filter, based on the frequency of the electric power.