Dual-Air Atomizer Unit for Fast-Response Minimum Lubrication
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Solution Overview
Problem
Current minimum quantity lubrication systems face challenges in optimizing response time and adjustability, especially in systems with small spindles where aerosol generation within the spindle is not possible due to space constraints, and there is a need to reduce coolant/lubricant usage while maintaining effective cooling and lubrication during machining processes.
Innovation Solution
An atomizer unit with a chamber arrangement that uses two compressed air streams to create a transport stream for the coolant/lubricant, allowing for precise and uniform distribution, with an injection valve for controlled dosing, enabling flexible and responsive lubrication, particularly suited for drilling processes with varying demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant/lubricant is sprayed into a chamber with a high-pressure nozzle and transported by compressed air stream, then the system can be designed as single-channel or two-channel minimum quantity lubrication system, but the response time and adaptability to changing requirements remain insufficient
Solution Approach 1:
The system is divided into two separate channels: a first supply channel for coolant/lubricant delivery and a second supply channel for compressed air. This segmentation allows independent control of each channel, enabling faster response to changing machining conditions without compromising the reliability of cooling and lubrication functions.
Solution Approach 2:
The system incorporates dynamic control capabilities where the first and second compressed air streams can be independently adjusted in terms of flow rate and pressure. This dynamic adjustability allows the system to rapidly adapt to varying machining requirements, improving response time while maintaining process reliability.
2Volume of moving object
If aerosol is generated outside the spindle and conveyed through the spindle, then space constraints in small spindles are avoided, but the reaction time and adaptability to changing conditions need further optimization
Solution Approach 1:
The dual-channel architecture segments the aerosol generation process into separate functional paths, allowing the system to maintain external aerosol generation (avoiding spindle space constraints) while introducing independent control mechanisms that enhance adaptability to changing machining conditions.
Solution Approach 2:
The system enables independent parameter adjustment of the first compressed air stream (for aerosol generation) and the second compressed air stream (for transport). This parameter independence allows rapid adaptation to varying conditions without requiring physical modifications to the spindle structure.
3Quantity of substance
If minimum quantity lubrication systems are used to reduce coolant/lubricant amount, then costs and environmental impact are reduced, but the homogeneity and uniformity of distribution need improvement
Solution Approach 1:
The system employs pneumatic transport using a first compressed air stream to generate and carry the aerosol, and a second compressed air stream to deliver it to the machining point. This pneumatic delivery mechanism ensures homogeneous and uniform distribution of the minimal coolant/lubricant quantity, achieving precise application without waste.
4Volume of moving object
If external minimum quantity lubrication systems are used that guide coolant/lubricant outside the tool, then space constraints are avoided, but the response time and precision of delivery to machining point need optimization
Solution Approach 1:
The external aerosol generation system uses high-velocity compressed air streams to rapidly transport the coolant/lubricant aerosol from the generation chamber to the machining point. This pneumatic delivery mechanism achieves high delivery speed comparable to internal systems while maintaining the space advantages of external configuration.
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 solution enhances the homogeneity and adjustability of coolant/lubricant distribution, reducing consumption and reaction time, allowing for efficient cooling and lubrication in machining processes, especially in drilling and riveting operations on aircraft structural components, while minimizing environmental impact.
Implementation Method 1
at least one first supply channel (10) for supplying a first compressed air stream (11) into and through the chamber arrangement interior (9) to a transfer channel (12)
Implementation Method 2
an injection valve (13) for injecting a coolant and/or lubricant (4) into an injection area (14) into the first compressed air stream (11) in the chamber arrangement interior (9)
Implementation Method 3
at least one second supply channel (15) for supplying a second compressed air stream (16) into and through the chamber arrangement interior (9) to the extension channel (12). The atomizing unit (2) is designed in such a way that the second compressed air stream (16) combines with the first compressed air stream (11) and any coolant and/or lubricant (4) injected into the first compressed air stream (11)
Implementation Method 4
The system described in DE 20 2009 017 656 U1 already exhibits improved response times compared to other minimum quantity lubrication systems... the coolant and/or lubricant is sprayed into a chamber with a high-pressure nozzle and transported to the machining point by means of a compressed air stream
Data Source
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AI summary
The invention relates to an atomizer unit of a minimal quantity lubrication system (3) for cooling and/or lubricating a chip-removing machining process between a tool (5) and a workpiece (6) at a machining station, wherein the atomizer unit (2) has a chamber arrangement (8) with a chamber arrangement interior (9), at least one first supply duct (10) for supplying a first compressed air stream (11) into and through the chamber arrangement interior (9) to a continuation duct (12) and an injection valve (13) for injecting a coolant and/or lubricant (4) into an injection region (14) into the first compressed air stream (11) in the chamber arrangement interior (9). It is proposed that the atomizer unit (2) has at least one second supply duct (15) for supplying a second compressed air stream (16) into and through the chamber arrangement interior (9) to the continuation duct (12), wherein the atomizer unit (2) is configured such that the second compressed air stream (16) joins the first compressed air stream (11), and any coolant and/or lubricant (4) injected into the first compressed air stream (11), downstream of the injection region (14) to form a transport stream (17) for transporting the injected coolant and/or lubricant (4), and wherein the transport stream (17) is conveyed through the continuation duct (12) to the machining station (7).