Machining Water Filtration with Resistivity Control for Filter Life
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing filter used to remove sludge from machining water has a short lifespan, particularly when processing aluminum workpieces, due to high resistivity of the water.
Innovation Solution
A machining water treatment device that includes a sewage tank, a clean water tank, a filter, and a system to control water circulation and supply, which reduces water resistivity by using low-resistivity water from a waterworks to extend filter life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water with high resistivity is used for machining aluminum workpieces, then the electrical discharge machining process is effective, but the filter lifespan is significantly reduced due to rapid degradation
Solution Approach 1:
The system performs preliminary action by proactively detecting water quality parameters (resistivity, temperature, contamination levels) and adjusting water composition before the filter reaches its degradation threshold. The controller continuously monitors and modifies water properties to prevent conditions that would accelerate filter degradation, thereby extending filter lifespan while maintaining machining effectiveness.
Solution Approach 2:
The system applies parameter changes by dynamically adjusting water resistivity, temperature, and chemical composition based on real-time sensor feedback. The controller modifies these parameters to optimize both the electrical discharge machining process and filter durability, finding the optimal balance between machining effectiveness and filter protection through continuous parameter adjustment.
2Productivity
If the filter operates continuously to remove sludge, then sludge removal efficiency is maintained, but the filter degrades faster and requires more frequent replacement
Solution Approach 1:
The system implements periodic action by cycling the filter operation and water regeneration processes. Instead of continuous high-intensity filtration that accelerates degradation, the controller periodically activates the filter and alternates with water composition adjustment phases, maintaining sludge removal efficiency while reducing cumulative stress on the filter media and extending its service life.
Solution Approach 2:
The system employs feedback control by continuously monitoring sludge accumulation levels, water quality parameters, and filter performance metrics. The controller uses this feedback to dynamically adjust filtration intensity and timing, optimizing the balance between maintaining effective sludge removal and minimizing filter degradation through adaptive, data-driven decision-making.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
One aspect of the present disclosure is a device for treating water for machining comprising: a wastewater tank that stores water discharged from a machining tank of an electrical discharge machine that performs electrical discharge machining of a workpiece; a filter that removes sludge contained in the water inside the wastewater tank; a freshwater tank that stores the water from which the sludge has been removed; a first water supply unit that supplies the water to the wastewater tank; and a first water discharge unit that discharges the water from the wastewater tank or the freshwater tank.