Pulse Width Modulated Coolant Distribution System
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Solution Overview
Problem
Maintaining the correct coolant concentration and level in metal working machines is labor-intensive and prone to errors due to evaporation and coolant loss, affecting part quality and tool life.
Innovation Solution
A coolant distribution system using two premixed streams at extreme concentrations, mixed using a pulse width modulation approach to achieve the desired concentration, which is automatically delivered to multiple machines via a manifold, controlled by a Programmable Logic Controller and sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual topping up of coolant is performed, then coolant level is maintained, but labor intensity increases and errors occur
Solution Approach 1:
The system enables self-service operation by automatically monitoring coolant levels and concentrations, and autonomously mixing and distributing coolant to multiple machines without human intervention. The PLC-controlled system performs all operations including level sensing, concentration control, and coolant distribution automatically.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated control system. The PLC (programmable logic controller) substitutes human operators, using electronic sensing and control mechanisms to monitor and regulate coolant distribution, eliminating manual labor while maintaining precise control over coolant concentration and levels.
2Manufacturing precision
If coolant concentration is not precisely controlled, then mixing process is simplified, but part quality and tool life are affected
Solution Approach 1:
The system achieves precise coolant concentration control by dynamically adjusting mixing parameters. The PLC controls the mixing process by varying flow rates and timing of coolant streams, enabling accurate concentration control (within ±1% accuracy) while managing system complexity through automated parameter adjustment rather than complex mechanical mixing mechanisms.
Solution Approach 2:
The patent implements feedback control through level sensors and concentration monitoring that continuously report back to the PLC. This closed-loop feedback system automatically adjusts the mixing process to maintain precise coolant concentration, ensuring manufacturing precision while the control system manages the complexity of the mixing operation.
3Productivity
If frequent manual coolant topping up is performed, then coolant level is maintained, but productivity decreases due to labor time
Solution Approach 1:
The system ensures continuous operation by automatically maintaining coolant levels and concentrations without interruption to machine operation. The automated distribution system continuously monitors and replenishes coolant as needed, eliminating the periodic stoppages and labor interventions required in manual systems, thus maintaining uninterrupted productive operation.
Solution Approach 2:
The coolant distribution system performs self-service by automatically detecting when coolant levels are low and initiating replenishment without human intervention. This eliminates the need for operators to spend time on manual topping up, freeing them to focus on productive tasks while ensuring coolant maintenance occurs continuously and automatically.
4Extent of automation
If automated coolant distribution is implemented, then labor is reduced, but system complexity increases
Solution Approach 1:
The system achieves high automation through a multi-functional PLC-controlled platform that handles level monitoring, concentration control, mixing regulation, and distribution to multiple machines. By consolidating these functions into a single automated control system rather than separate complex mechanisms for each function, the system achieves extensive automation while managing overall complexity through functional integration.
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 precise and repeatable coolant concentration control, eliminating the need for manual topping up and reducing labor, while maintaining optimal coolant levels and preventing rusting by accurately mixing coolant streams.
Implementation Method 1
Mixing the two streams follows a pulse width approach, in which pulses of the coolant are produced having modulated pulse volume to provide a flow of a desired concentration
Data Source
AI summary
A coolant distribution system uses two premixed streams of coolant at either extreme of a concentration range, and mixes these two streams in the correct percentage to obtain the desired concentration. Mixing the two streams follows a pulse width approach, and the system may use a manifold to deliver fluid to multiple machines.