Rolled Filter Media for Electrical Discharge Machine
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Solution Overview
Problem
Existing working fluid filtering devices for electrical discharge machines face issues with clogging due to fine metal sludge accumulation, leading to reduced filtration capability and potential fluid leakage from worn-out seal contacts, limiting the use of low-filtration accuracy filter media and preventing backwashing for reuse.
Innovation Solution
A working fluid filtering device with a rolled filter media system that includes a filter supply roll, collection roll, movement detection, and a control unit to manage seal contact and pressure, allowing for increased filtration pressure without damaging the device or media, enabling backwashing and reuse of the filter media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If filtration pressure is increased to improve filter flow rate, then filtering capability is improved, but the filter media and filter vessel may be damaged due to exceeding their strength limits
Solution Approach 1:
The invention applies dynamic pressure control by periodically varying the filtration pressure rather than maintaining constant high pressure. The control unit adjusts the pressure based on detected clogging levels, allowing the system to operate at higher pressures when the filter is clean and reduce pressure when the filter approaches its strength limit, thus improving productivity while preventing damage to the filter media
Solution Approach 2:
The invention implements a feedback control mechanism where a detection unit monitors the clogging level of the filter media in real-time. This feedback information is used by the control unit to dynamically adjust the filtration pressure, ensuring that pressure is increased to improve flow rate only when safe, and reduced when the filter media approaches its strength limit, resolving the contradiction between productivity and strength
2Duration of action of moving object
If rolled filter media is moved through the filter tank to enable continuous filtration, then filtration continuity is improved, but the seal and filter media contact parts wear out due to rubbing
Solution Approach 1:
The invention applies beforehand cushioning by providing a buffer zone or protective layer between the moving filter media and the seal contact surfaces. This cushioning mechanism reduces the direct rubbing and friction between the filter media and seal, allowing continuous filtration to proceed while minimizing wear and maintaining seal integrity over extended periods
Solution Approach 2:
The invention uses flexible seal materials or thin film protective layers that can adapt to the movement of the rolled filter media. These flexible elements conform to the changing geometry of the moving filter while maintaining the sealing function, reducing mechanical stress and rubbing wear on both the seal and filter media during continuous operation
3Reliability
If filter media with low filtration accuracy is used to prevent seal wear, then seal reliability is improved, but filtering capability for fine metal sludge deteriorates
Solution Approach 1:
The invention applies dynamic pressure control that compensates for the lower filtration accuracy of coarser filter media. By optimizing and varying the filtration pressure dynamically, the system maximizes the filtering capability of the available media, allowing fine metal sludge to be effectively removed even with media that has larger pore structures, while maintaining seal reliability through reduced wear
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
The system effectively filters fine metal sludge without damaging the device or media, extends the life of the filter media by allowing backwashing and reuse, and prevents fluid leakage by maintaining seal integrity, thus enhancing filtration efficiency and reducing maintenance costs.
Implementation Method 1
a rolled filter media and moving the rolled filter media without damaging either the working fluid filtering device or the filter media
Data Source
AI summary
A seal is brought into contact with a filter media, a filter pump is operated to start filtration, and a signal from a pressure sensor is received. When a predetermined value is exceeded by the signal from the pressure sensor, the filter pump is stopped, the seal is separated from the filter media, and take-up of one section of the filter by a filter collection roll is started. In finishing filter supply from a filter supply roll, drive of a motor is stopped, and an alarm signal is transmitted. If the supply is not to be finished, one section of the filter is taken up by the filter collection roll, and the next stage of filtration is entered.