Sensor Calibration for Cooling Lubricant Emulsion Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for determining the parameters of cooling lubricant emulsions in machine tools are prone to errors due to oily deposits on sensors, leading to incorrect concentration calculations, which can result in reduced cutting performance, increased tool wear, and susceptibility to corrosion and microbiological attacks.
Innovation Solution
A method involving calibration of sensors using fresh cooling lubricant emulsion with a defined concentrate-to-water ratio, allowing for accurate measurement and correction of sensor readings, and the use of a device with a sensor block, mixing block, and feed pump to condition and monitor the emulsion, ensuring precise determination of parameters and addition of additives as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are used to measure cooling lubricant emulsion parameters continuously, then monitoring reliability is improved, but measurement precision deteriorates due to oily deposits on sensors
Solution Approach 1:
The patent applies preliminary action by performing calibration measurements with fresh emulsion of known concentration before actual monitoring operations. This pre-calibration step establishes baseline sensor readings that account for any deposits or contamination present on the sensor at the time of calibration, thereby correcting subsequent measurements without requiring continuous manual intervention.
Solution Approach 2:
The system implements feedback by continuously comparing current sensor readings against the calibration baseline and automatically adjusting concentration calculations accordingly. The control unit receives real-time sensor data, compares it with the calibrated reference values, and computes corrected emulsion parameters, providing continuous feedback correction that compensates for sensor drift and contamination effects.
2Measurement precision
If sensor calibration is performed frequently to maintain precision, then measurement accuracy is improved, but device complexity and operational time increase
Solution Approach 1:
The patent performs calibration measurements in advance using fresh emulsion with known concentration values before the actual monitoring period begins. This preliminary calibration establishes reference data that remains valid for the entire monitoring cycle, eliminating the need for frequent recalibration interruptions and reducing operational complexity.
Solution Approach 2:
The system enables self-service calibration by automatically using the known concentration of fresh emulsion as the reference standard. The control unit automatically compares subsequent sensor readings against this pre-established baseline and performs self-correction without requiring external intervention or complex manual calibration procedures, thereby simplifying the overall process.
3Measurement precision
If fresh cooling lubricant emulsion is used for sensor calibration, then measurement precision is improved, but loss of substance increases due to emulsion consumption
Solution Approach 1:
The patent uses a small volume of fresh emulsion with known concentration for preliminary calibration measurements before the actual monitoring operation. This limited initial consumption establishes the calibration baseline, and the same fresh emulsion can then be used as the reference standard throughout the monitoring period without requiring continuous additional consumption for calibration purposes.
Solution Approach 2:
The system changes the parameter approach by transitioning from continuous calibration to a single pre-established calibration baseline. Instead of continuously consuming fresh emulsion for calibration, the system uses the known concentration parameter of the fresh emulsion as a static reference value that corrects all subsequent measurements, thereby reducing ongoing substance loss while maintaining precision.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention proposes a method for determining at least one parameter and/or for conditioning a cooling lubricant emulsion for machine tools (110, 110'), wherein the cooling lubricant emulsion is removed from a tank (60, 60'), at least one parameter of the cooling lubricant emulsion is detected using at least one sensor (41, 42, 43), and at least some of the cooling lubricant emulsion is fed back into the tank (60, 60'). The method further comprises at least one of the following steps: i) calibrating the at least one sensor (41, 42, 43), by rinsing the at least one sensor (41, 42, 43) and carrying out a measurement with fresh cooling lubricant emulsion, which has a defined ratio of a concentrate to water, ii) carrying out a measurement in which a sample is taken from the tank (60, 60'), the sample is guided past the at least one sensor (41, 42, 43) continuously in a circuit to detect at least one parameter of the sample, at least one measuring reagent being added continuously or incrementally and the at least one parameter being continuously measured until the at least one parameter reaches a predefined threshold value, and then, at least some of the sample is fed back into the tank (60, 60'). A further aspect of the invention relates to a device that is configured to carry out the method.