Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional application Ser. No. 61/913,553 filed on Dec. 9, 2013. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    In automated machining of parts such as engine components, the machining takes place at machine stations, each station enclosed to form a booth. A coolant/lubricant liquid is sprayed onto the part during the machining operations in order to reduce friction and cool the part. 
         [0003]    This spraying creates a fine mist which is intended to be confined within the booth in order to prevent the mist from being dispersed into the air within the plant, where it could be inhaled by plant personnel and present a health hazard. Also, the mist can condense onto adjacent surfaces, creating a maintenance burden. 
         [0004]    Oil in the coolant/lubricant can also evaporate from the mist into the air and create an air pollution problem. 
         [0005]    In order to minimize this effect, the conventional practice has been to constantly draw a large volume of air out of the booths and into ducting with a fan driven by a powerful electric motor drawing considerable power. This is intended to prevent the mist from dispersing into the air in the plant. The ducting leads to a central filter/demister where the mist is completely removed from the air before being discharged back into the atmosphere. 
         [0006]    The coolant/lubricant condensed from the mist is collected and directed back to the machine station for reuse. 
         [0007]    It has heretofor been recognized that it is advantageous to remove as much mist as possible at a location close to the machine tool station rather than transporting all of it to a central demisting location in order to reduce the quantity of mist transported through the ducting to the central unit. This is because leaking of condensed mist from the ducting, and evaporation of the oil in the mist into the air can both occur in the ducts, which effects will contribute to the air pollution problem mentioned above. In addition, condensed water can aid the growth of mold and creation of a fire hazard. Also, less mist flowing in the ducts reduces the maintenance efforts required in cleaning the ducting through which the mist flows. 
         [0008]    Furthermore, high efficiency air filters (HEPA) are used to completely remove the residual mist, and these filters would rapidly become blocked if all of the mist were to reach those filters, greatly increasing maintenance costs since HEPA filters are very expensive. 
         [0009]    A decentralized demister arrangement is described in U.S. Pat. Nos. 8,266,945 and 7,727,295, incorporated herein by reference, as well as in a TMI brochure published in 2002, referenced in those patents. 
         [0010]    The volume of air flow drawn out of a CNC machine booth is conventionally set at a high flow rate which is thought necessary to prevent escape of oily mist from the machining booth at any time during the machine cycle, and also to insure proper operation of the cyclonic separator. 
         [0011]    That is, the cyclonic separators typically used have usually required high air flow rates through them in order to be effective. 
         [0012]    It is an object of the present invention to provide a demister arrangement for machine tool installations which greatly reduces the power consumption required while insuring that no mist escapes from the machining booth at any time. 
       SUMMARY OF THE INVENTION 
       [0013]    The above recited object as well as other objects which will be understood by those skilled in the art upon a reading of the following specification and claims is achieved by reducing the rate of air flow drawn from the machining booth to that minimally necessary to insure that no mist escapes the machine tool booth. This is achieved by varying the volume of air flow drawn out from the booth to a low level which is all that will be needed during those periods when the access doors to the machining center booth enclosure are closed, to a maximum air flow drawn from the booth when the doors are opened, as when loading and removing parts being machined in the station. 
         [0014]    The differing out flow rates are preferably achieved by using a variable frequency drive (VFD) control on a fan motor used to draw air from the booth, to significantly reduce the total power consumption of the fan motor by reducing the power to the fan motor from a level when full output is required to a reduced level of air flow out adequate to maintain a vacuum level in the booth. This will insure that no mist containing air escapes from the enclosure booth at any time during the machining operation. 
         [0015]    It has been determined that a particular cyclonic separator of a type described in U.S. Pat. No. 7,311,744, incorporated herein by reference when operated in a “vertical up” mode has the capability of operating successfully to remove mist over the range of air outflow rates through the separator which is necessary to substantially minimize power consumption of the fan motor over the machine cycle. 
         [0016]    A similar situation is presented in a multi-station installation, when the fan motor conventionally is set to always run to produce the air outflow rate necessary to prevent out flow of booth air, when all stations are operating. In the present invention, an automatic step down of the fan motor operation is carried out if fewer machining stations are on line, so that a significantly lower air out flow rate will suffice, to also conserve power. 
         [0017]    Additionally, the fan motor may be controlled to vary in correspondence to the flow resistance encountered in the demister filters, i.e., the fan motor power can set at a minimal level when the filters are clean and increased as the HEPA and/or other filters at the central demister become more clogged. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a pictorial view of a machining booth with a connected demister/filter apparatus and a block diagram representation of associated controls therefore according to the present invention. 
           [0019]      FIG. 1A  is an enlarged sectional view of a typical duct joint showing a sealed connection. 
           [0020]      FIG. 2  is a diagram of a second stage demister/filter with block diagram depiction of control sensor components. 
           [0021]      FIGS. 3A ,  3 B and  3 C are diagrams of alternative control schemes which could be utilized to vary the fan motor power. 
           [0022]      FIG. 4  is a plot of efficiency versus air flow rate of the cyclonic separator used in the apparatus and method of the present invention. 
           [0023]      FIG. 5  is a side view of the cyclonic separator as used in the invention. 
           [0024]      FIG. 5A  is a longitudinal cross section of the cyclonic separator shown in  FIG. 5 . 
           [0025]      FIGS. 6 and 7  are downstream and upstream end views, respectively, taken along the lines 6-6 and 7-7 in  FIG. 5 . 
           [0026]      FIG. 8  is a perspective view of the cyclonic mist separator shown in  FIGS. 5-7 , with portions of the cyclonic mist separator housing being cut-away for clarity to showing certain internal components. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims. 
         [0028]    Referring to  FIG. 1 , a machining center booth  10  is shown which encloses a conventional automated CNC machining station (not shown) in which parts are machined with the use of metal cutting tools in the well known manner. 
         [0029]    The parts are typically unloaded after one or more access door panels  12  are opened, as indicated in  FIG. 1  by load/unload robots or other part handling devices (not shown), which then load parts to be machined into the machines, with the access door panels then closed. 
         [0030]    As noted, such machining operations use metal cutting tools which involve the use of cutting fluids sprayed on the part and tools in the well known manner. This generates mist such as from oil, water vapor, synthetic coolant, etc. which is designed to be confined within the booth  10  in order to prevent the mist from escaping into the surrounding air where it would present the various problems referred to above. 
         [0031]    This is done conventionally by continuously drawing the air into which the mist has dispersed out from booth  10  and into ducting  14  by operation of a blower  16  which is driven by a powerful electric motor  18  ( FIG. 2 ). The blower  16  may be contained within a central separator/filter apparatus  20 . 
         [0032]    This is air flow drawn out of the machining center booth is continuously maintained so as to make certain that none of the mist containing air escapes the confines of the machining center booth  10  except dispersed in this flow of air drawn out by the blower  16 . 
         [0033]    As described above, it is now known that it is desirable to remove as large proportion of the mist at points close to each booth  10 , rather than directing the mist laden air to a central filter/demister before removing any of the mist, as was the former practice. 
         [0034]    Again, this is because movement of the air containing the mist through long ducts increases the evaporation of oils into the atmosphere to create air pollution, and finally, partially condenses the mist therein, to create a fire hazard, and mold growth, creates a maintenance burden due to the necessity for regular cleaning of the ducts. This also necessitates pumping of condensed coolant back to the machining stations for reuse. 
         [0035]    Thus, it is now common practice to install a first stage separator  22  immediately above the enclosure  10 , which collects condensed mist liquid that is drained back into the reservoir of cutting fluids in the machine tool in the booth  10 , as by gravity via a drain line  24 . 
         [0036]    Referring to  FIG. 2 , the details of a central demister/filter apparatus  20  are shown with the fan motor  18  and fan  16  mounted within a housing  56  located above aluminum mesh washable prefilter  58 ; and 95% DOP HEPA filter  64 . The top insures substantially all of the mist is removed from the air flow prior to its discharge into the outlet  66  and thence into the atmosphere. 
         [0037]    The air inlet  53  (connected to ducting  14 ), receives air flow at a point below the prefilter  58  and is drawn up by operation of the blower  16 . 
         [0038]    Condensed mist drawn from the prefilter  58  and final filter  64  is collected at the bottom of the housing  55  and drains back by gravity or is pumped back to the station via pipe  65  ( FIG. 1 ). 
         [0039]    The machine control  70  receives a signal from a sensor (not shown) detecting when the panels  12  are open or closed such that a variable frequency (VFD)  72  drive control is operated to normally run the fan motor  18  at a substantially reduced power setting which is still adequate to maintain vacuum levels exist within the booth  10  to present the escape of air, i.e., when the panels  12  are closed, and at a stepped up power level only when the access door panels  12  are opened. 
         [0040]    There are several ways contemplated by the present invention to determine when and to what extent the air flow drawn out of the booth  10  must be varied over the course of operation of the machining station to achieve the benefits of the present invention. 
         [0041]    Firstly and preferably, the machine controls  70  transmits a signal to the VFD drive control  72  when the door panels  12  are about to be opened by the machine controls  70  for the unloading and loading of parts, such that the blower motor  18  power can be stepped up to a much higher level, predetermined to be adequate to reliably insure mist containing air will not escape from the booth  10 . 
         [0042]    This approach allows anticipation of the need for increased air flow so that the shift to a higher flow rate can be initiated before the access door panels open and thus actually be developed by the time the door panels  12  are opened. 
         [0043]    This requires integration with the machine controls  70  which may require the cooperation of those responsible for the machine tool operation. 
         [0044]    An alternative approach is depicted in the arrangement of  FIG. 3A , in which changes in air flow are sensed such as by measuring the pressure drop across the first stage separator  22  with a differential pressure sensor  74  connected to pressure taps  76  on either end of the separator  22 . 
         [0045]    As the door panels  12  begin to open, the air flow and pressure drop will begin to increase due to the reduced restriction of the air flow entering the booth  10 . In response, the power level of the fan motor  18  is correspondingly ramped up, set by a control  78  acting on the VFD  72 . 
         [0046]    Such sensor differential pressure can be measured anywhere in the system to detect increases in the air flow drawn out of the machining center booth  10 . 
         [0047]    Another alternative approach is depicted in  FIG. 3B , where one or more vacuum sensors  80 ,  82  are provided within the machining center booth  10  at one or more locations therein in order to sense vacuum level changes anywhere within the machining center booth  10 . 
         [0048]    As the access door panels  12  begin to open, the vacuum level within the enclosure booth  10  will begin to lessen, i.e., the pressure in the booth  10  will begin to increase, so that the vacuum level will begin to decline. 
         [0049]    This reading will be sent to control  78  which acts on the VFD to cause a corresponding increase in power of the blower motor  18  as in  FIG. 3A  as necessary to maintain the vacuum level. 
         [0050]    As the vacuum level start to move higher as the door panels  12  begin to close, this is sensed by the sensors  80 ,  82  and the air flow rate reduced accordingly. 
         [0051]      FIG. 3C  shows yet another alternative approach in which a switch  84  is associated with one or more of the access door panels  12  which generate when the associated access door panel  12  begins to open. Again, this causes the control  78  to generate a signal transmitted to the VFD  72  increasing the power to the blower  18  to increase the outflow of air from the enclosure booth  10 . 
         [0052]    Other arrangements may be used that will achieve this same result. 
         [0053]    The mist separator  22  is advantageously of a particular cyclonic design generally described in U.S. Pat. No. 7,311,744, although in a modified form. 
         [0054]    It has been discovered that such a separator particularly as modified can function successfully to remove a high proportion of mist from the air flow directed therethrough over a substantial range of air flow rates through the separator  30  such that considerable variations in the rate of flow of the air being drawn through the separator  30  is possible while maintaining a high degree of demisting at the enclosure booths  10 . 
         [0055]    Referring to  FIGS. 5-10 , the separator  30  includes a cylindrical, tubular housing  32  that defines a cylindrical inside wall  34  (see  FIGS. 5-7 ), and that is connected between aligned inlet and exit end couplings  36   b  and  36   a  provided with associated inlet  96  and exit  97  openings and adapted for connection to the ducting  14  such that mist contaminated air enters as indicated at  40   g  and pre-cleaned air exits as indicated at  40   a.    
         [0056]    Internal stationary vanes  38  are connected in the upstream and downstream end portions of the housing  32 . The vanes  38  are sized and positioned to establish and maintain a cyclonic air flow pattern such as indicated at  40   b  downstream thereof. The cyclonic flow causes the moisture to migrate outwardly as indicated at  40   c  to the inside wall  34 , and to flow downwardly along the surface of the inside wall  34  as indicated at  40   d . To this end, a separation chamber  56  is defined between the vanes, generally in the center portion of the housing, and is characterized as being of generally open, unobstructed construction as shown for maximum separation of moisture from the swirling air flowing therethrough. 
         [0057]    In preferred embodiments, the vanes  38  are used at both the upstream and downstream ends. Between the inside wall  34 , longitudinally spaced center supports  52   a ,  52   b  provide for relatively stiff cyclonic-flow vane structure. 
         [0058]    A liquid collection chamber  42  is located at the bottom portion of the separator  30  to collect the liquid flowing along the inside wall  34 , and to direct the liquid to a drain  44 . The liquid collection chamber also establishes a barrier to prevent the liquid from being sucked back into the air as it exits the separator such that, once the liquid enters the chamber, it is generally trapped therein. The collection chamber is an annular, dead-ended space provided with an annular entrance opening that is coincident with the inside wall  34  of the housing such that liquid flowing in the upstream direction along the inside wall of the separation chamber flows directly into the collection chamber as indicated at  40   e.    
         [0059]    The collection chamber may be defined between the outside diameter (OD) of an inlet tube  48  that extends in the downstream direction from the inlet coupling  96 , the inside diameter (ID) of the housing wall  34 , a downstream end wall  54   b  of the housing. For separators as here intended to be used in a generally vertical orientation, the drain hole  44  is preferably positioned with its downstream open edge coincident with or slightly downstream of the radially outer edge of the end wall  54   b  (to the left as shown in  FIG. 5 ) to preclude a dead-space behind the drain hole in which liquid cold accumulate. 
         [0060]    In the collection chamber  42 , the liquid continues to flow in a generally circular pattern such as indicated at  40   f  in  FIG. 6 . Upon reaching the downstream end and bottom of the collection chamber, circulation of the liquid is interrupted by a flow-interrupter  50  that projects into the collection chamber in the downstream end portion proximate the downstream wall  54   b . The flow interrupter is shaped to direct the liquid flowing around the collection chamber to the drain  44 . The flow interrupter is preferably provided in the form of a generally radially inwardly extending wall portion that breaks the swirling flow at the drain. 
         [0061]    To this end, the flow interrupter is connected or located just downstream of the drain with respect to the swirling flow of liquid therein, and is provided in a form that includes at least a first portion that projects generally longitudinally along the wall  34 . In preferred embodiments, the flow interrupter is further provided with a second portion that extends generally substantially circumferentially from the first portion such as the L-shaped hood shown that extends over and above the drain hole, or in the form of a curved-hood that curves over and above the drain hole. It has been found that, in most instances encountered, the hood extending to a position over the drain hole is preferred as providing better direction of the liquid into the drain as compared with, for example, a straight interrupter consisting of only the first generally radially projecting portion. 
         [0062]    For use in existing mist collection systems, the separator  30  is preferably adapted for relatively low air pressure drop. This allows use of the separator to be used within the air-flow capacity of the fan of the existing system. To this end, the separator may be provided with upstream and downstream annular walls  54   a ,  54   b  that extend radially outwardly from associated inlet and exit couplings  36   b ,  36   a  proximate the inlet and exit openings, and the inside wall  34  extends therebetween to define an upstream expansion chamber into which the air flow enters upon flowing through the inlet opening and in which stationary vanes are located, the inside diameter of the wall  34  being preferably approximately one-fourth to one-third larger than the diameter of the hoses and end couplings  36   a ,  36   b  (i.e., the diameter of the inlet and exit openings) for a relatively low pressure drop embodiment. 
         [0063]    By way of dimensional example, one of the common size hoses currently used in mist collectors are six inch hoses. In this instance, it has been found that a cylindrical wall ID of eight inches, with end coupling of six inches diameter, provides relatively low pressure drop; and that for vanes extending longitudinally approximately four and one-hale (4½) inches, with the leading edges set at an angle of approximately 25 degrees with respect to the upstream opening face (as seen in  FIG. 5 ), and extending longitudinally therefrom at an angle of approximately 35 degrees with respect to a longitudinal axis therethrough, provides good cyclonic action in the separator. 
         [0064]    It has also been found that a flow restrictor adapted to provide a radial clearance of approximately one-fourth (¼) to one-half (½) inch, and preferably three-eighths (%) inch allows the liquid to enter the collection chamber  42 , while providing good restriction to prevent the liquid from leaving the chamber. In this example, as well as other similarly sized units such as for eight inch hoses provided with a ten inch ID wall and a flow restrictor cone radial clearance of approximately three-eighths inch, removal of between 85-95% of the mist from the air has been consistently achieved, with a relatively low pressure drop. 
         [0065]    It will also be understood, however, that for new design systems where the pressure drop may be permitted to increase or decrease, because the capacity of the fan has not yet been established (as compared to existing mist collections systems with an already installed fan), the dimensional difference between the end couplings and the inside diameter of the housing may be increased or decreased. 
         [0066]    It has also been found that the optimum size and number of vanes to establish the desired cyclonic action will vary depending on the size of the cylindrical wall  34 . Continuing with the above dimensional examples, it has been found that three vanes of suitable size provide good cyclonic action in a separator with a six inch ID, and five vanes may be required in the larger ten inch housing. 
         [0067]      FIG. 3  shows the performance of the cyclonic mist separator  22  over a range of flow rates, showing that effective demisting is achieved over a substantial range of air flow rates, thus allowing the variation in air outflow rates while still achieving effective demisting at the machine.

Technology Category: 7