Abstract:
A system provides for the delivery of lubricant or coolant to multiple machines simultaneously. The system comprises a single source of fluid where the single source is fluidly connected to a controller. The controller has a plurality of fluid connections to workstations. At least one fluid conduit extends between the controller and each workstation. Each workstation has means for applying the lubricant or coolant to a predetermined location. The locations are tools, workpieces, or drive components such as motors, bearings, gears, and the like. The lubricant or coolant is applied by an applicator, stream nozzle, or spray nozzle. The scrap material from the processing application is in condition for resale, instead of disposal.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims the benefit of U.S. provisional application Ser. No. 60/522,251, filed Sep. 7, 2004, which is incorporated herein in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The invention relates to a system for distributing lubricants and coolants to multiple machine workstations from a single source. More particularly, the invention relates to a controlled system for delivering metered quantities of lubricants and coolants, as needed, to machines, including their working parts, and workpieces in manufacturing or other industrial operations. In addition, the invention relates to a method of processing workpieces and recovering clean scrap material from the processes.  
       DESCRIPTION OF THE RELATED ART  
       [0003]     In industrial operations, particularly in cutting and machining operations on hard materials such as metals, it has long been recognized that it is highly desirable to apply liquid lubricants or coolants to the cutting tools or workpieces, and often to the motors and power tools as well, throughout duty cycles. Different processing operations involving tools and workpieces often have differing requirements for lubricants and coolants. Similarly, power tools and their moving parts, such as power motors, have differing requirements for coolants and lubricants.  
         [0004]     It is common, for example, to deliver a continuous stream of coolant to a tool during a machining operation on a workpiece. One of the natural consequences of this process is a need to recover the coolant, filter any scrap particles machined from the workpiece, and otherwise store or recycle the coolant. Often the coolant is petroleum based so that the resulting coolant must be disposed of according to the requirements of hazardous waste disposal. Recycling and filtering of coolant and disposal of waste is very costly.  
         [0005]     Sometimes coolants and lubricants must be delivered alternately to a workstation, and other times coolants and lubricants must be delivered simultaneously. The advent of automated equipment such as Computer Numeric Control (CNC) machining has added complexity to the problems of satisfactorily and timely delivering coolants and lubricants where needed.  
         [0006]     It is also known to apply lubricants and coolants to advancing workpieces as they pass a particular location by contact with an applicator member. This is particularly advantageous for processing continuously advancing stock such as roll forming. An example of such a contact lubricator can be found in U.S. Pat. No. 5,849,086.  
         [0007]     It is also known to apply lubricants and coolants in mist or “atomized” form by, for example, spraying from an appropriate nozzle. When applied in mist form, a comparable amount of fluid can cover a larger surface area of the target object than when it is applied as a stream, thus adding efficiency and economy to the lubricating/cooling process. Typically, the fluid is dry, i.e., light, water-based fluid from an oil concentrate that is delivered under pressure and combined with air at a nozzle to be sprayed on the workpiece.  
         [0008]     Normally, because of the wide variety of machines, workstations, and processes, and their disparate requirements for delivery of coolants and lubricants, delivery systems are provided at the workstation, and controlled at the workstation. Such mechanisms can be found in commonly-owned U.S. Pat. Nos. 5,669,743, 5,542,498 and 6,213,412, all of which are incorporated herein by reference.  
         [0009]     There remains a need for reliable and efficient system for delivering coolants and lubricants to different workstations involving different processes at lower cost and with a minimum of waste.  
       SUMMARY OF THE INVENTION  
       [0010]     According to the invention, a system is provided for delivering lubricants or coolants to multiple workstations. The system comprises a single or multiple source(s) of lubricants or coolants fluidly connected to a controller, and a plurality of fluid connections between the controller and multiple workstations. Each fluid connection is at least one fluid conduit that extends between the controller and a single workstation. Each workstation has means to apply the lubricant or coolant to a predetermined location in response to signals from the controller.  
         [0011]     Preferably, the lubricants or coolants are near dry. The system is ideal where two workstations have different requirements for lubricants or coolants. The system is easily adapted for the single source to be pressurized. Preferably, the controller is programmable. Also, the system can include a compressed air source and a pneumatic connection between the compressed air reservoir and at least one workstation. In this manner, the flow of air via the pneumatic connection can be controlled by the controller.  
         [0012]     In one aspect, a second fluid connection can be provided between the controller and at least one workstation. The workstation typically has a drive portion adapted to work on a workpiece. In accord with the invention, the controller controls the delivery of lubricants or coolants to the drive portion through one fluid connection, and to the workpiece through the second fluid connection. The workstation can have a slave controller to provide signals to the controller based on unique parameters of the workstation.  
         [0013]     In another aspect, a system is provided to deliver lubricants or coolants to a single workstation having a drive portion adapted to work on a workpiece. The system comprises a source of lubricants or coolants fluidly connected to a controller, and at least two fluid connections between the controller and the workstation. The workstation has means to apply the lubricant or coolant to the drive portion through one fluid connection, and to the workpiece through the second fluid connection in response to signals from the controller.  
         [0014]     Preferably, the lubricants or coolants are applied in minimal amounts, and may be in near dry form. Also, preferably, the source is pressurized. Typically, the controller will be programmable. The system can include a compressed air reservoir and a pneumatic connection between the compressed air reservoir and the workstation. Thus, the flow of air via the pneumatic connection can be controlled by the controller.  
         [0015]     In another aspect of the invention, a method of recycling waste material from a processing operation is provided. The method includes the steps of providing a workpiece at a workstation, processing the workpiece, while using a near dry lubricant/coolant, into a finished workpiece and scrap, separating the scrap from the finished workpiece, and selling the scrap for market value.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     In the drawings:  
         [0017]      FIG. 1  is a schematic diagram showing a first embodiment of a system according to the invention.  
         [0018]      FIG. 2  is a schematic diagram showing a second embodiment of the system according to the invention.  
         [0019]      FIG. 3  is a schematic diagram showing one of the workstations of the system and  FIG. 2 .  
         [0020]      FIG. 4  is a schematic diagram showing another of the workstations of the system in  FIG. 2 .  
         [0021]      FIG. 5  is a perspective view of a portion of another of the workstations of the system in  FIG. 2 .  
         [0022]      FIG. 6  is an illustration of the drilling machine at one of the workstations of the system in  FIG. 2 .  
         [0023]      FIG. 7  is an illustration of a milling machine at one of the workstations of the system in  FIG. 2 .  
         [0024]      FIG. 8  is an illustration of a screw machine at one of the workstations of the system in  FIG. 2 .  
         [0025]      FIG. 9  is an illustration of a turning machine at one of the workstations of the system in  FIG. 2 .  
         [0026]      FIG. 10  illustrates a method of processing and recovering scrap material according to the invention.  
     
    
     DETAILED DESCRIPTION  
       [0027]     The lubricant and coolant delivery system according to the invention has three important aspects. First,  FIG. 1  illustrates the general concept of the centralized delivery to a plurality of workstations. Second,  FIGS. 2-8  illustrate in greater detail an exemplary delivery system with a variety of delivery modes. And third,  FIG. 9  illustrates a method of workpiece processing and scrap material recovery that is achieved by implementation of a delivery system in accordance with the invention.  
         [0028]     Looking now at the first aspect of the invention in  FIG. 1 , a lubricant and coolant delivery system  10  includes a fluid supply  12  fluidly connected to a controller  14  by a conduit  16 . The fluid supply  12  will typically be a reservoir holding the desired lubricant or coolant. Preferably, the fluid supply  12  is pressurized. It is within the scope of the invention, however, for the fluid supply  12  to be unpressurized, in which case the conduit  16  can be pressurized by way of a pump (not shown), for example.  
         [0029]     The controller  14  is ideally a programmable device capable of controlling the flow of lubricant or coolant to a plurality of workstations  18 ,  20 ,  22 ,  24 , and  26 . Each workstation is fluidly connected to the controller  14  by a corresponding conduit  19 ,  21 ,  23 ,  25 , and  27 . An example of a controller  14  that might be suitable for the present application can be found in commonly-owned U.S. Pat. No. 6,567,710, the entire disclosure of which is incorporated herein by reference.  
         [0030]     It is contemplated that each of the workstations  18 ,  20 ,  22 ,  24 , and  26  may be identical or may be different. It is further contemplated that there may be more or less workstations without departing from the scope of the invention. Each workstation, of course, might have different requirements for the specific localized delivery of lubricant or coolant. For example, workstation  18  may be a continuous processing application that would require a contact applicator of the type found in U.S. Pat. No. 5,849,086, the entire disclosure of which is incorporated herein by reference. Similarly, workstation  20  might be a tapping machine of the type incorporating a fluid dispensing system as disclosed in U.S. Pat. No. 5,669,743, the entire disclosure of which is incorporated herein by reference. Instead of having a separate reservoir of fluid in the localized dispensing unit, the conduit  21  will deliver fluid to the local dispensing unit at the workstation  20 .  
         [0031]     Workstations  22 ,  24 , and  26  might be, for example, a drilling machine, a milling machine, a screw machine, and a turning machine respectively. It would be expected that the typical processes operated at workstations  22 ,  24 , and  26  may require a pulse action mist lubrication system as disclosed in U.S. Pat. No. 5,542,498 or a spray head assembly as disclosed in U.S. Pat. No. 6,213,412. Both of these patents are incorporated herein by reference. For those deliveries at workstations requiring compressed air, an air reservoir  28  is provided with conduits directed to those workstations that may require compressed air. See, for example, conduits  30 ,  32 , and  34 . It will be understood that any or all of the workstations may require compressed air. In fact, it is within the scope of the invention for a conduit to connect the compressed air reservoir  28  to the controller  14 , or for the flow of air to be controlled by the controller  14  and delivered through conduits adjacent to or coaxial with conduits  19 ,  21 ,  23 ,  25 , and  27 .  
         [0032]     Looking now at  FIGS. 2-8 , where like numerals reflect like components to those illustrated in  FIG. 1 , a second aspect of the invention contemplates delivery of lubricant/coolant to drive portions of the workstations through one set of conduits  36 ,  38 ,  40 ,  42 , and  44 , and delivery of lubricant/coolant to tools and workpieces at the workstations through another set of conduits  46 ,  48 ,  50 ,  52 , and  54 . Moreover, each workstation  18 ,  20 ,  22 ,  24 , and  26  will have one or more sensors (not shown) or slave controllers (not shown) that provide signals to the controller  14  (see dotted lines). Such signals will be electrical and can be transmitted over wires or wirelessly. The slave controllers will cooperate with the main controller to coordinate the flow of fluids through the conduits and the specific application of lubricant/coolant to a given point.  
         [0033]      FIGS. 3 and 4  schematically illustrate the delivery of lubricant/coolant to exemplary workstations  18  and  22 , respectively, following the examples assumed above. Workstation  18  comprises an apparatus  60  for driving a continuous workpiece through rollers, and a continuous applicator  62  for applying the lubricant/coolant to the workpiece. Fluid conducted through conduit  36  from the controller  14  enters a valve  64  which will control the delivery of lubricant to the roller bearings  66  and to the drive motor  68 . Fluid directed through the conduit  46  from the controller  14  enters local valve  68  that locally controls delivery to the applicator  62 . Because the applicator  62  provides a continuous stream, compressed air is not necessary and therefore there is no compressed air conduit to workstation  18 .  
         [0034]     Workstation  22 , on the other hand, is a drill machine having a variety of tools and a variety of drive components, some of which are illustrated schematically in  FIG. 4 . Here, lubricant/coolant in conduit  40  is delivered to a local valve  70  where it is then directed to drive components such as drive bearings  72 , drive motor  74 , or tool turret bearings  76  for normal lubrication of those components, as needed. The lubricant/coolant in conduit  50  from the controller  14  is directed through a valve  78  to either or both a spray nozzle  84  for a drill and a spray nozzle  82  for the workpiece. It will be understood that there may be multiple spray nozzles for multiple tools and more than one spray nozzle for the workpiece. It will also be understood that the lubricant/coolant used for the drive components through conduit  40  might be different that the lubricant/coolant delivered through conduit  50 . In such case, there may be two fluid supplies (not shown) that deliver the respective lubricant/coolants to the controller. Similarly there may a separate controller for each lubricant/coolant, as needed. In any event, as is commonly known, compressed air is provided through conduit  30  where it is combined with lubricant/coolant at the spray heads for distribution as a mist. Preferably, conduit  30  is coaxial with the conduit ( 40  or  50 ) that delivers the lubricant/coolant so that atomization occurs at the nozzle. But, it is within the scope of this invention for the conduit  30  to be separate from the conduit  40  or the conduit  50  delivering the lubricant/coolant. Either way, it is preferable for atomization to occur at the nozzle, although it has been known to atomize the lubricant/coolant upstream of the nozzle. The problem with the latter is that the lubricant/coolant may precipitate prior to reaching the nozzle. In any event, as is known from the prior art, the spray of lubricant/coolant can be pulsed or continuous, as described in the previously referenced and incorporated U.S. Pat. Nos. 5,542,498 and 6,213,412.  
         [0035]     The preferred lubricant is a non-petroleum based oil, such as vegetable-based oils, preferably applied in minimal amounts. When the vegetable based oils are applied in atomized form, they form an essentially “near dry” lubricant. That is, the near dry lubricants leave very little to no residue on the scrap, unlike prior petroleum-based oil bath applications, which left the scrap with a heavy coat of oil. The minimal residue associated with near dry lubricants is partly related to the lower volumes of lubricant used as compared to prior lubricants and the tendency of the lubricant to evaporate when they contact the heated scrap. The application of the near dry lubricant through a mist or atomized forms aids in reducing the volume of lubricant. Also, the vegetable lubricant provides approximately double the friction reduction properties and has about double the heat capabilities before burning.  
         [0036]     Also, a local controller  86  can communicate with the main controller  14  (not shown in  FIG. 4 ) as shown by dotted line  88 . Such control can be wired or wireless. Likewise, the local controller  86  provides relevant signals to the valves  70 ,  78  by way of signal path  90  to direct operation thereof, as needed. It will be understood that sensors at the drive components, tools and workpieces can transmit relevant signals either directly to the controller  14  or to the local controller  86  for retransmission to the controller  14 . Processing of the signals can occur either at the local controller  86 , the main controller  14  or both.  
         [0037]      FIGS. 5-8  illustrate exemplary workstations showing the dual nature of the lubricant and coolant distribution system in accordance with the invention, where lubricant is directed to drive components as well as tooling and workpieces. In  FIG. 5 , a contact applicator  92  comprises a pair of vertically opposed, horizontally extending cylindrical rollers  94 ,  96  that are mounted in trough like housings  98 ,  100 . The position of the upper row or  96  is adjustable by a pneumatic cylinder  102 . Lubrication of this pneumatic cylinder  102  is provided from the controller (not shown) in accordance with the invention through conduit  104 . Similarly, lubricant/coolant is provided to the rollers  94 ,  96  in accordance with the invention through conduits  106 .  
         [0038]      FIG. 6  illustrates a drill machine  110  that generally comprises a table  112  mounted for movement on a base  114 . Movement of the table  112  relative to the base  114  is accomplished by drive motor  116 . A column  118  disposed adjacent the table  112  carries a tool turret  120 , rotatably mounted to the column. The tool turret  120  carries a plurality of drills  122 , each drill being driven by a controllable motor  124 . The tool  120  is typically mounted to the column on a shaft  126 . Coolant supply tubes  128  extend from the column  118 , and are adjustable relative to a workpiece  130 . The drill machine  110  is controlled by a local controller  132 . In accordance with the invention, lubricant will be provided to the drive components, including the drive motor  116 , the controllable motor is  124 , and the tool turret shaft  126  from a single source. Similarly, lubricant/coolant will be provided through coolant tubes  128  to the workpiece while the drilling process occurs. The lubricant/coolant will be provided from a remote, single source through the same delivery system as the lubricant provided to the drive components. Preferably, the lubricant/coolant provided to the workpiece  130  will be a pulsed, non petroleum-based mist.  
         [0039]      FIG. 7  illustrates a milling machine  140  that generally comprises a table  142  mounted for movement on a base  144 . Movement of the table  142  relative to the base  144  is accomplished by drive motor  146 . A column  148  disposed adjacent the table  142  carries a mill head  150 , disposed for rotation on the column  148 . The mill head  150  carries a cutting tool  152  that is driven by a motor  154 . Coolant supply tubes  156  extend from the column  148 , and are adjustable relative to a workpiece  158 . The milling machine  140  is controlled by a local controller  160 . In accordance with the invention, lubricant will be provided to the drive components, including the drive motor  146  and the mil motor  154  from a single source. Similarly, lubricant/coolant will be provided through coolant tubes  156  to the workpiece  158  while the milling process occurs. The lubricant/coolant will be provided from a remote, single source through the same delivery system as the lubricant provided to the drive components. Preferably, the lubricant/coolant provided to the workpiece  158  will be a pulsed, near dry mist.  
         [0040]      FIG. 8  illustrates a screw machine  170  that generally comprises a table  172  mounted to a base  174 . A drive motor  176  in the base  174  is operatively connected to a gearbox  180  that drives a turret slide  182  on a carrier screw  184 . A spindle  186  is driven by a drive motor  188  in a control drum  190 . Coolant supply tubes  192  extend from a back wall  194 , and are adjustable relative to a workpiece (not shown). The screw machine  170  is controlled by a local controller  196 . In accordance with the invention, lubricant will be provided to the drive components, including the drive motor  176 , gearbox  180 , carrier screw  184 , and drive motor  188  from a single source. Similarly, lubricant/coolant will be provided through coolant tubes  192  to the workpiece while the screw process occurs. The lubricant/coolant will be provided from a remote, single source through the same delivery system as the lubricant provided to the drive components. Preferably, the lubricant/coolant provided to the workpiece will be a pulsed, non petroleum-based mist.  
         [0041]      FIG. 9  illustrates a turning machine  210  that generally comprises a bed  212  on which is fixedly mounted a head stock  214  and on which is moveably slidably mounted a tail stock  216 . A spindle  218  with a chuck  219  is provided with the head stock  214 . A quill  220  is provided with the tail stock  216 . The workpiece is mounted between the spindle  218  and quill  220  for rotation in response to the rotation of the spindle. A turret  222  is slidably mounted to the bed  212  and mounts a variety of tools  224  for performing different machining operations be it cutting, facing or the like.  
         [0042]     In accordance with the invention, lubricant will be provided to the drive components, including the spindle  218  from a single source. Similarly, lubricant/coolant will be provided through coolant tubes  192  to the workpiece while the turning process occurs. The lubricant/coolant will be provided from a remote, single source through the same delivery system as the lubricant provided to the drive components. Preferably, the lubricant/coolant provided to the workpiece will be a pulsed, non petroleum-based mist.  
         [0043]     Looking now at  FIG. 10 , the overall method afforded by the instant invention using near dry lubricant/coolant is illustrated. Processing occurs at a workstation  200  on a workpiece  202 . During processing, near dry lubricant/coolant comprising a non-petroleum-based fluid such as flaxseed oil is atomized to the spray head and delivered either continuously or pulsed to the tool and/or workpiece. Material that is removed from the workpiece during processing is collected and separated from the workpiece as scrap. Finished workpieces  204  are collected for further disposition such as further processing, assembly, or delivery to the customer. Scrap material is now in a condition to be resold  206  rather than disposed of as waste. Furthermore, because near dry lubricant/coolant is used in limited quantities, there is no need for a costly fluid recovery system, and no concern with hazardous waste.  
         [0044]     While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.