Milling Cooling Mode Switching by Real-Time Depth Detection
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Solution Overview
Problem
Current machining technologies face inefficiencies in switching between internal and external cooling lubrication modes, particularly in machining deeper holes and grooves, leading to suboptimal cooling and increased resource wastage, with manual switching requiring significant human resources and lacking intelligent control.
Innovation Solution
An intelligent switching system that collects milling depth data, analyzes it in real-time, and automatically switches between internal and external cooling modes using a vision system, control center, and motor control to determine the most suitable cooling lubrication mode based on preset thresholds, thereby optimizing cooling performance without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal cooling mode is used for machining deeper holes and grooves, then cooling lubrication effect is improved, but system cost increases and economic waste occurs when internal cooling is not needed
Solution Approach 1:
The system dynamically switches between internal cooling mode and external cooling mode based on real-time machining conditions (milling depth). The switching is controlled by a control center that receives milling depth data and automatically adjusts the cooling configuration, making the system adaptable rather than static.
Solution Approach 2:
The system uses its own milling depth detection capability to automatically determine when to switch cooling modes without external intervention. The control center processes the milling depth data and triggers the appropriate cooling mode autonomously.
2Adaptability or versatility
If manual switching between internal and external cooling modes is implemented, then cooling mode can be adjusted, but significant human resources are required and switching efficiency is low
Solution Approach 1:
The manual mechanical switching operation is replaced by an automated control system that uses electrical/electronic signals to switch between cooling modes. The control center receives data, processes it, and automatically actuates the switching mechanism without human physical intervention.
Solution Approach 2:
The system continuously monitors milling depth through detection and feeds this information back to the control center, which then adjusts the cooling mode accordingly. This closed-loop feedback mechanism enables automatic adaptation to changing machining conditions.
3Area of stationary object
If external cooling mode is used, then cooling coverage is improved, but cutting fluid utilization rate is extremely low causing economic loss and health hazards
Solution Approach 1:
Instead of continuously applying external cooling in excessive amounts, the system applies cooling partially and selectively based on actual machining needs. External cooling is activated only when milling depth exceeds the threshold, reducing unnecessary cutting fluid consumption.
Solution Approach 2:
The system changes the operational parameters of the cooling system by switching between different cooling modes (internal/external) based on milling depth. This parameter change optimizes cutting fluid utilization by matching cooling application to actual thermal requirements.
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 system ensures optimal cooling lubrication mode selection, reducing resource wastage, improving machining accuracy, and significantly reducing labor costs by automating the switching process between internal and external cooling modes based on real-time machining conditions.
Implementation Method 1
a vision system to collect milling depth data
Implementation Method 2
The cooling effect of the cutting fluid is realized by taking heat away from the cutter and the workpiece, through convection and vaporization between the cooling fluid and the cutter, cuttings and the workpiece
Implementation Method 3
The cooling effect of the cutting fluid is realized by taking heat away from the cutter and the workpiece, through convection and vaporization between the cooling fluid and the cutter, cuttings and the workpiece
Implementation Method 4
The lubrication effect of the cutting fluid is realized via a partial lubrication film which is formed due to reducing friction between a front cutter surface and the cuttings, as well as friction between a rear cutter surface and a machined surface
Data Source
AI summary
An intelligent switching system for switching internal cooling and external cooling and a method are provided. The system includes a vision system, a cooling system and a control system. The vision system monitors a real-time milling state of a cutter, collects a real-time milling depth image that the cutter mills a workpiece, and transmits the collected real-time milling depth image to the control system. The control system includes a lubrication mode control center, and a motor control center. The lubrication mode control center receives the real-time image transmitted by the image collection control center; analyzes and processes the real-time image to obtain real-time milling depth data of the cutter. The motor control center receives a signal sent by the lubrication mode control center; analyzes and processes the signal, and transmits a control instruction to the cooling system. The cooling system executes a switching command issued by the control system.