Coordinated Mist Removal System for Machine Tool Energy Optimization
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Solution Overview
Problem
Existing mist removal systems in machine tools and factories are inefficient due to continuous operation of mist collectors, leading to wasteful power consumption and inadequate mist concentration control, as they lack coordinated control of multiple units and are not optimized based on varying factory conditions and machine tool operations.
Innovation Solution
A coordinated mist removal system that includes observation units to measure and estimate mist concentration, and control units to interlock the operation of machine tool and factory mist countermeasure units, such as mist collectors and air conditioners, to efficiently reduce mist concentration by determining control details based on observation results and positional relationships.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mist collectors operate continuously, then mist concentration is suppressed, but power consumption increases wastefully during idle periods
Solution Approach 1:
The mist collector's operation state is dynamically adjusted based on real-time mist concentration detection. The system transitions from continuous static operation to dynamic on-demand operation, activating the mist collector only when mist concentration exceeds predetermined thresholds, thereby eliminating wasteful power consumption during idle periods while maintaining effective mist suppression when needed
Solution Approach 2:
The system implements feedback control by using detection units to monitor mist concentration and feed this information back to the control unit. The control unit then adjusts the mist collector's operation accordingly, creating a closed-loop control system that optimizes power consumption based on actual mist conditions rather than operating continuously
2Productivity
If multiple mist countermeasure units are operated simultaneously, then mist removal efficiency improves, but power consumption increases
Solution Approach 1:
The system applies partial action by selectively activating only the necessary number of mist countermeasure units based on detected mist concentration levels. Instead of operating all units simultaneously, the control unit activates units in a staged manner, using more units only when mist concentration is high, thereby achieving effective mist removal while minimizing power consumption
Solution Approach 2:
The operation of multiple mist countermeasure units is dynamically coordinated based on real-time conditions. The system transitions from static simultaneous operation to dynamic selective operation, adjusting which units are active based on their positional relationships to mist sources and current factory conditions, optimizing both efficiency and energy use
3Reliability
If mist collectors are positioned close to machine tools, then local mist concentration is reduced, but device complexity increases
Solution Approach 1:
The system applies local quality by positioning mist collectors at specific locations based on their proximity to mist sources and airflow patterns. Each mist collector is strategically placed to address local mist generation zones, with the control unit coordinating their operation based on detected mist concentrations at different locations, thereby achieving effective local suppression without requiring uniform distribution of devices throughout the factory
Data Source
AI summary
A mist removal system includes an observation unit that observes a situation related to the mist concentration in a factory, a first mist countermeasure unit that reduces the mist concentration in a machine tool, a second mist countermeasure unit that reduces the mist concentration in the factory, and a control unit. The control unit controls observation by the observation unit and interlocking operation of the first mist countermeasure unit and the second mist countermeasure unit. Furthermore, the control unit determines the control details of interlocking operation of the first and second mist countermeasure units based on the observation results of the mist concentration obtained by the observation unit.