Dynamic Coolant Control in Machine Tools
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Solution Overview
Problem
Existing methods for controlling coolant and lubricant supply in machine tools often result in excessive usage, leading to high energy costs and oversized infrastructure, as they do not accurately determine the precise volume required for machining processes.
Innovation Solution
A method that determines the removal behavior of auxiliary materials based on tool speed, workpiece material properties, and machining parameters, using three-dimensional CAD models and mathematical erosion models to model the cooling and lubricant requirements dynamically, ensuring precise volume flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant and lubricant supply is controlled using conventional M commands based on machining status, then the cooling and lubrication function is provided, but excessive volume flow is supplied leading to high energy costs and oversized infrastructure
Solution Approach 1:
The patent applies dynamics by transitioning from static, pre-programmed coolant control to dynamic control that continuously adapts the coolant volume flow based on real-time machining conditions. The control device calculates the actual cooling and lubrication requirements during machining and adjusts the volume flow accordingly, ensuring the system responds dynamically to changing demands rather than following fixed M commands.
Solution Approach 2:
The patent implements parameter changes by modifying the coolant volume flow parameter based on calculated requirements. Instead of using fixed volume flow rates defined in the NC program, the system continuously adjusts the volume flow parameter according to the actual machining state, material properties, and thermal conditions, thereby optimizing energy consumption while maintaining adequate cooling and lubrication.
2Reliability
If coolant and lubricant supply is controlled using conventional M commands, then the basic cooling and lubrication is achieved, but far more auxiliary materials are supplied than actually required
Solution Approach 1:
The patent applies self-service by enabling the control device to autonomously determine and adjust the coolant volume flow based on calculated requirements. The system uses the control device's own computational capabilities to analyze machining parameters, material properties, and thermal conditions, then automatically regulates the auxiliary material supply without external intervention, eliminating the need for excessive predetermined supply.
Solution Approach 2:
The patent implements feedback by continuously monitoring machining conditions and using this information to adjust the coolant volume flow. The control device receives data about the current machining state, calculates the actual cooling and lubrication requirements, and feeds this information back to the coolant supply system to optimize the volume flow, ensuring only the necessary amount of auxiliary materials is supplied.
3Reliability
If excessive coolant volume flow is supplied, then adequate cooling and chip washing is ensured, but the line network must be oversized and energy costs increase
Solution Approach 1:
The patent applies partial action by supplying only the portion of coolant volume flow that is actually required for effective cooling and chip washing, rather than using an excessively high volume flow rate. The control device calculates the minimum necessary volume flow based on thermal and lubrication requirements, enabling the line network to be appropriately sized without the need for oversized infrastructure designed to handle excessive flows.
4Loss of energy
If precise determination of auxiliary material requirements is implemented, then energy costs and infrastructure requirements are reduced, but complex modeling of removal behavior and temperature distribution is required
Solution Approach 1:
The patent applies universality by designing the control device to perform multiple functions: it not only controls the coolant supply but also calculates removal behavior, models temperature distribution, determines thermal states, and optimizes volume flow rates. This multi-functional approach consolidates complex modeling and control tasks into a single integrated system, reducing the need for separate specialized devices while achieving precise energy optimization.
Data Source
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AI summary
The invention relates to a method and a device for controlling auxiliary materials in machine tools, wherein the volumetric flow of the auxiliary material is switched on and off (cooling lubricant on, cooling lubricant off) by means of a numerical control using machine functions in the form of an M code, wherein while the volumetric flow flows, a control variable (cooling lubricant controlled) for the volumetric flow of the auxiliary material is obtained from the path position or machining position, known in the numerical control in the form of a G code, of a tool of the machine tool and from the current physical parameters of the tool and/or of the machined workpiece.