External Cooling MQL Nozzle Positioning for Real-Time Tool Changes
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Solution Overview
Problem
Current external cooling MQL manipulators require manual adjustment of nozzle positions, which is time-consuming and inefficient, especially when the length of the cutter changes during processing.
Innovation Solution
An automated external cooling MQL manipulator with a robot arm, motor-driven connecting and oil ejecting rods, a controller, and an oil mist generator that adjusts lubrication parameters in real time based on processing conditions, including a microcontroller or PLC for precise control and an oil mist generator with an air compressor, pneumatic pump, and mixing valve to generate oil mists.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment of nozzle positions is used, then device complexity is reduced, but productivity deteriorates due to time-consuming adjustments
Solution Approach 1:
The nozzle position is made dynamically adjustable through motor-driven mechanisms. The connecting rod and oil ejecting rod can rotate to different positions based on processing requirements, transforming a static manual adjustment system into a dynamic automated system that adapts to changing cutter lengths and processing conditions.
Solution Approach 2:
Manual mechanical adjustment is replaced with an automated control system comprising a controller, detecting components, and motor-driven mechanisms. The controller receives signals from detecting components and automatically actuates the motors to adjust nozzle positions, eliminating manual intervention and significantly improving adjustment speed.
2Loss of time
If manual adjustment of nozzle positions is used, then device complexity is reduced, but loss of time increases due to repeated adjustments
Solution Approach 1:
The detecting components continuously monitor processing conditions and cutter length in advance, allowing the controller to pre-calculate and prepare the appropriate nozzle position before adjustment is needed. This proactive approach minimizes waiting time and ensures immediate adjustment when processing conditions change.
Solution Approach 2:
A closed-loop feedback system is implemented where detecting components monitor processing conditions and cutter length, send signals to the controller, which then adjusts the nozzle position accordingly. This real-time feedback mechanism eliminates the need for repeated manual adjustments by automatically responding to changing conditions, significantly reducing adjustment time.
3Productivity
If automated real-time adjustment is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives signals from detecting components, processes processing condition data, calculates optimal nozzle positions, controls motor actuation, and monitors adjustment completion. This multi-functional integration consolidates what could be multiple separate systems into a single coordinated controller, improving productivity while managing complexity through functional integration.
Solution Approach 2:
The system is designed to be self-regulating and self-adjusting. The detecting components automatically monitor processing conditions, the controller autonomously calculates required adjustments, and the motor-driven mechanisms self-actuate to position the nozzle correctly. This self-service capability eliminates the need for external manual intervention, significantly improving processing efficiency while the integrated control architecture manages system complexity.
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
Enables real-time adjustment of lubrication positions and parameters, optimizing lubrication and cooling effects, reducing lubricant waste, and stabilizing workpiece quality by automatically adapting to changing processing conditions.
Implementation Method 1
compressed gases and trace amounts of lubricant are mixed to form oil mists containing micron droplets
Implementation Method 2
mixed to form oil mists containing micron droplets
Implementation Method 3
the oil mists are ejected into cutting areas at a high speed via a nozzle
Implementation Method 4
the first motor is in transmission connection with the connecting rod and is configured to drive the connecting rod to rotate
Implementation Method 5
the second motor is configured to drive the oil ejecting rod to rotate
Data Source
AI summary
This application relates to lubrication, and more particularly to an external cooling MQL manipulator and a machine tool and a lubrication method using the machine tool. The external cooling MQL manipulator includes a suspension structure, a robot arm, a controller and an oil mist generator. The suspension structure fixedly connects the robot arm and a frame, and a nozzle is provided on a free end of the robot arm; an oil mist generator is connected to the nozzle for ejecting oil mists to a processing area. When the machine tool works, the controller selects the corresponding lubrication parameters according to the processing parameters such as the cutter type and the workpiece material. The first motor and the second motor are controlled to rotate by the controller according to real-time changes of the processing positions detected by the detecting component, thereby adjusting the position of the nozzle.