Sheet Spray Lubrication With Electronic Valve Frequency Control
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Solution Overview
Problem
Existing spray lubrication systems for metal sheets in cold plastic deformation processes lack accurate control over spraying frequency, leading to excessive lubricant use and waste.
Innovation Solution
Implementing electronically adjustable solenoid valves with conical shutters, controlled by a central unit, allows precise adjustment of lubricant application, including heating and temperature monitoring, and includes vacuum extraction to minimize mist and ensure uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanically or electro-pneumatically adjusted spraying valves are used, then the system structure is simple, but the spraying frequency control accuracy is poor leading to lubricant waste
Solution Approach 1:
The patent replaces mechanical or electro-pneumatic valve adjustment mechanisms with an electronic control system that uses solenoid valves actuated by electronically adjustable frequency signals. This substitution enables precise digital control of spraying frequency while maintaining relatively simple hardware architecture.
Solution Approach 2:
The patent changes the control parameter from mechanical position or pneumatic pressure to electronically adjustable frequency signals. By controlling the frequency of electrical pulses to solenoid valves, the system achieves accurate spraying frequency control that can be precisely tuned and adjusted without mechanical complexity.
2Ease of operation
If higher lubrication pressures are used to ensure adequate lubricant delivery, then the lubricant distribution becomes uneven and oil mist increases, but lower pressures may insufficiently deliver lubricant
Solution Approach 1:
The patent uses periodically actuated solenoid valves that open and close at precisely controlled intervals. This periodic action delivers lubricant in controlled pulses rather than continuous flow, enabling uniform distribution at lower average pressures and reducing oil mist generation by minimizing excessive spray exposure.
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
Achieves precise lubricant application with reduced pressure, minimizing waste and optimizing distribution on metal sheets.
Implementation Method 1
Each valve (7) is provided with a nozzle (8) for delivering oil spray. The valves (7) are of the electronic adjustable spraying frequency type and comprise a conical needle shutter so that it is actuated by means of a solenoid
Implementation Method 2
The system (1) comprises heating means of the lubricant before it is pumped into the spraying heads (5, 6)
Implementation Method 3
An extractor creates a vacuum near the spraying head to aspirate the oil mist which is generated in the immediate proximity of the sheet during its lubrication
Data Source
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AI summary
The invention relates to a spray lubrication system of sheets provided with electronically adjustable frequency spraying valves. Said valves are grouped into modules including four valves each, housed at two spraying heads, one lower and one upper. The lubrication system comprises three motorized rolls on which a sheet to be lubricated can be placed to make it transit between the spraying heads. Said sheet, when placed on the rolls, can be clamped between them and a plurality of contrast wheels housed on two radial expansion pneumatic shafts, also motorized. Said clamping prevents involuntary movements of the sheet during its transit between the spraying heads. The radial expandability of motorized shafts makes it possible to position the contrast wheels appropriately as a function of the shape of the sheet to be lubricated. The system which is the object of the invention also comprises multiple sensors for monitoring and adjusting the temperature of the sprayed lubricant. A first group of motion sensors for detecting whether the aforesaid sheet passes at each spraying valve or not further present in front of the lower spraying head. By virtue of said first group of sensors, the system which is the object of the invention can self-learn the shape of the sheet to be lubricated. A second group of motion sensors is installed at both spraying heads to detect whether a lubricant spraying is present or not at each valve. By virtue of a second group of sensors, the system which is the object of the invention can diagnose a malfunction whenever a discrepancy is found between the spraying frequency controlled to a valve and whether a spraying is present or not at each valve. The upper spraying head is housed in a box for aspirating the oil mists which are generated by the lubrication system during the work cycle.