Dual-Air Atomizer Layout for Fast Minimal Lubrication Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing minimal-quantity lubrication systems face challenges in reaction time and adjustability, particularly in machining installations with small spindles where aerosol generation inside the spindle is not possible, and there is a need for improved control over coolant and lubricant usage to minimize waste and optimize machining processes.
Innovation Solution
An atomizer unit with a chamber arrangement that uses two compressed-air streams to create a transport stream for coolant and lubricant, allowing for precise and flexible distribution, with an injection valve for pulsing high-pressure injection to enhance homogeneity and reaction speed, and a nozzle design for efficient atomization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If aerosol generation is performed inside the spindle, then reaction time is improved and adaptability to changing conditions is enhanced, but structural space requirements cannot be met in small spindles
Solution Approach 1:
The atomizer unit is segmented into multiple functional chambers (injection chamber, atomizer chamber, mixing chamber) that can be arranged in a compact configuration. This segmentation allows the system to achieve aerosol generation functionality outside the spindle while maintaining a space-efficient design that could potentially integrate with small spindles.
Solution Approach 2:
The system transitions from internal spindle aerosol generation to external aerosol generation, changing the spatial dimension of the atomizer unit from inside to outside the spindle. This dimensional change resolves the space constraint while maintaining reaction time performance through optimized external chamber arrangement.
2Speed
If high pressure injection is used, then reaction speed and atomization quality are improved, but energy consumption and system complexity increase
Solution Approach 1:
The injection valve operates with periodic pulsing rather than continuous high-pressure injection. This periodic action maintains high reaction speed and atomization quality during the injection phase while reducing overall energy consumption by allowing pressure relief and system recovery phases.
Solution Approach 2:
The system employs dynamic pressure control where the injection pressure is adjusted based on operational requirements. The injection valve can modulate pressure levels, providing high pressure when needed for rapid injection and atomization, then reducing pressure to minimize energy consumption during transport and maintenance phases.
3Loss of substance
If minimal quantity of coolant and lubricant is used, then cost and environmental impact are reduced, but adequate cooling and lubrication at the machining location becomes difficult to achieve
Solution Approach 1:
The system changes the physical parameters of the coolant and lubricant by transforming them into an aerosol state. This parameter change from liquid to aerosol form increases the surface area and dispersal of the lubricant, enabling effective cooling and lubrication with minimal quantities while maintaining reliability at the machining location.
Solution Approach 2:
The system uses compressed air streams to transport and deliver the aerosolized coolant and lubricant to the machining location. This pneumatic delivery mechanism ensures precise targeting and efficient distribution of minimal quantities, maintaining effectiveness while reducing overall consumption and waste.
4Stability of the object's composition
If two compressed-air streams are used for transport, then homogeneity and distribution quality are improved, but device complexity increases
Solution Approach 1:
The system merges two compressed-air streams (first transport air stream and second transport air stream) with the aerosol in a mixing chamber to achieve homogeneous distribution. This merging approach consolidates the complexity into a single mixing zone rather than requiring separate complex delivery systems, simplifying the overall device structure while maintaining homogeneity.
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 enables rapid and precise control over coolant and lubricant delivery, reducing waste and optimizing machining processes, especially in drilling and riveting operations, by ensuring uniform and adjustable aerosol distribution, even with small spindles and hybrid workpieces.
Implementation Method 1
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)
Implementation Method 2
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)
Implementation Method 3
downstream of the injection region (14), the second compressed-air stream (16) combines with the first compressed-air stream (11) and with the coolant and/or lubricant (4) possibly injected into the first compressed-air stream (11), to form a transport stream (17)
Implementation Method 4
a nozzle (22) for atomizing the injected coolant and/or lubricant (4), in particular with the first compressed-air stream (11)
Data Source
AI summary
An atomizer unit of a lubrication system has a chamber arrangement having a chamber arrangement interior, at least one first supply duct for supplying a first compressed-air stream into and through the chamber arrangement interior to a continuation duct, and an injection valve for injecting a coolant and/or lubricant into an injection region into the first compressed-air stream in the chamber arrangement interior. The atomizer unit has at least one second supply duct for supplying a second compressed-air stream into and through the chamber arrangement interior to the continuation duct. The atomizer unit is designed in such a manner that the second compressed-air stream combines with the first compressed-air stream and with the coolant and/or lubricant possibly injected into the first compressed-air stream, to form a transport stream for transporting the injected coolant and/or lubricant, and the transport stream is routed through the continuation duct to the machining location.