Optical Lubricant Flow Measurement at Outlet Nozzle
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Solution Overview
Problem
Existing methods for measuring coolant and lubricant flow in minimum-quantity lubrication systems are inadequate for detecting the actual flow at the outlet nozzle, as they rely on indirect measurements and are prone to errors due to leaks, tool movement, and environmental factors, leading to unreliable process control and potential tool damage.
Innovation Solution
A testing device with a light source, light-sensitive sensor, and measuring plate or filter made from materials with changing translucency, which accumulates coolant or lubricant and alters light transmission, allowing for direct measurement of flow at the outlet nozzle, enabling precise determination of low flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If indirect measurement methods (pressure sensors, flow turbines) are used in the coolant supply line, then flow measurement is possible, but measurement precision deteriorates due to leaks, tool movement, and environmental factors affecting the actual flow at the outlet nozzle
Solution Approach 1:
The invention extracts the measurement function from the indirect supply line measurement to direct outlet nozzle measurement. The light source and sensor are positioned to measure the actual coolant/lubricant flow emerging from the outlet nozzle directly, eliminating the influence of leaks and tool movement that occur in the supply line.
Solution Approach 2:
The invention introduces an intermediary measuring element (the light-absorbing material or liquid crystal layer) that interacts with the coolant/lubricant flow to convert the flow information into an optical signal. This intermediary enables precise measurement of the actual flow at the outlet by translating fluid dynamics into detectable light intensity changes.
2Measurement precision
If optical sensors are used in the coolant supply line, then flow measurement is possible, but measurement precision deteriorates because the analysis area becomes soiled, falsifying measurement results
Solution Approach 1:
Instead of placing the optical sensor in the coolant supply line where it would be exposed to soiling, the invention inverts the approach by placing the light source and sensor on opposite sides of the outlet nozzle, measuring the flow as it emerges. The measurement area is now the outlet nozzle itself, which is less susceptible to soiling during operation.
Solution Approach 2:
The measurement function is extracted from the vulnerable supply line environment and relocated to the outlet nozzle environment. By measuring at the outlet where the coolant/lubricant is delivered, the system avoids the soiling problems that occur in the supply line while maintaining measurement precision.
3Loss of substance
If flow rates are reduced to 10-50 ml/h for cost and environmental reasons, then coolant/lubricant consumption is minimized, but reliability deteriorates as process temperature rises and tool service life falls
Solution Approach 1:
The invention implements feedback control by continuously measuring the actual coolant/lubricant flow at the outlet nozzle and using this information to maintain process reliability. The precise flow measurement enables real-time monitoring and adjustment, ensuring that the minimum necessary flow is delivered to prevent temperature rise and tool damage while minimizing consumption.
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 solution provides reliable, direct measurement of coolant and lubricant flow at the point of use, improving process control and tool longevity by accurately determining the amount of fluid reaching the processing point, even under real-world conditions.
Implementation Method 1
The coolant and/or lubricant emerging from the outlet nozzle wets a measuring plate and/or a measuring filter, with the translucency of at least the measuring plate or of the measuring filter depending on the wetting with the coolant and/or lubricant
Implementation Method 2
at least one light source that emits light radiation during operation, a light-sensitive sensor that is in signal communication with evaluation and output electronics for determining a coolant and/or lubricant flow from the signal of the light-sensitive sensor
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The apparatus (10) has a light source (11) e.g. LED, radiating light radiation (12), and a display electronics circuit (17) determining flow of cooling agent and lubricant e.g. mineral oil. A measuring volume is provided between the source and a light-sensitive sensor e.g. color sensor, where a measuring plate (14) and measuring filter (13) e.g. depth filter, are provided in the volume. The plate and the filter are made of a material e.g. satined glass, whose translucency is changed by the agent and lubricant so that the sensor is illuminated by the light radiation. An independent claim is also included for a method for testing a minimum-quantity lubrication system for detecting cooling agent and/or lubricant flow.