Chip-Laden Liquid Treatment via Immersed Cutting Unit
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Solution Overview
Problem
Existing systems for collecting and recycling cooling lubricant emulsions in machine tools often malfunction due to the accumulation of metal chips, which can overload the cutting mechanism and disrupt the pumping process, leading to interruptions and inefficiencies.
Innovation Solution
The method separates the function of crushing chips from the liquid pumping process, using a cutting mechanism to reduce coarse chip content before returning the liquid to the collection tank, allowing for continuous operation and adaptable shredding performance, and includes a valve arrangement to control chip size and pump operation based on demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cutting mechanism is integrated into the pump to crush chips, then chip crushing function is improved, but the pump becomes prone to malfunctions due to chip accumulation and overload
Solution Approach 1:
The system is divided into two independent functional units: a cutting mechanism for chip crushing and a pump for liquid transport. The cutting mechanism is positioned upstream and processes chips before the pump draws in liquid, allowing each component to specialize in its function without interfering with the other's reliability.
Solution Approach 2:
The harmful factor (chips) is extracted and processed separately from the main pumping operation. The cutting mechanism removes and comminutes chips from the liquid stream before the pump operates, preventing chips from entering the pump and causing malfunctions.
2Productivity
If the pump operates continuously to maintain liquid circulation, then productivity is improved, but pump downtime occurs when liquid level is low or no cooling lubricant is required
Solution Approach 1:
The cutting mechanism operates continuously to comminute chips regardless of pump status, ensuring chips are always processed. The pump can be stopped when not needed without affecting chip processing, and the system quickly resumes when liquid circulation is required, minimizing overall downtime.
Solution Approach 2:
The system allows dynamic operation modes where the pump can be stopped or started based on liquid level and processing requirements, while the cutting mechanism maintains continuous operation. This dynamic control optimizes productivity by keeping critical functions active while allowing non-critical functions to rest when unnecessary.
3Manufacturing precision
If the cutting mechanism processes all chips, then chip size control is improved, but the system becomes complex with multiple cutting mechanisms
Solution Approach 1:
The cutting mechanism is designed to perform partial crushing of chips, reducing them to a manageable size rather than complete comminution. This partial action is sufficient to prevent pump malfunctions while keeping the cutting mechanism simple and avoiding the need for multiple stages or additional cutting devices.
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 approach prevents malfunctions by reducing chip overload on the suction pump, enabling continuous machine tool operation, and allows for flexible shredding capacity and controlled chip size, reducing downtime and pump switching issues.
Implementation Method 1
a cutting mechanism which is immersed in the liquid and has a rotating cutting wheel
Implementation Method 2
the liquid is sucked in from the bottom of the collecting basin by means of a cutting mechanism
Data Source
Figure 1
Figure 2
AI summary
Method for treating a chip-laden liquid (16) in a collection basin (10), characterized in that the liquid (16) is drawn from the bottom (12) of the collection basin (10) by means of a cutting unit (18) immersed in the liquid and having a rotating cutting wheel (32), and after the chips have been crushed, is immediately returned to the collection basin by the cutting unit.