TWI891369B - Method and system for monitoring quality of pure-oil-type of metal working fluid - Google Patents

Abstract

The application discloses a method and a system for monitoring the quality of pure-oil-type of metal working fluid. A sampling step is firstly performed to obtain a sample from the metal processing oil circulated in a rolling equipment, and then the sample is subjected to a moisture content analysis step to obtain a moisture content detection value. Next, a determining step is performed to compare the moisture content detection value of the sample and a control range to correspondingly generate a determining result. An adjusting step is performed based on the determining result.

Description

Quality monitoring method and system for pure oil-based metalworking fluids

The present invention relates to a monitoring method and system, and in particular to a quality monitoring method and system for pure oil-based metalworking fluids.

Rolling primarily utilizes rollers to apply stress, causing deformation in metal materials. The rolling oil used during this process provides lubrication to prevent roller abrasion of the material surface. However, the quality and performance of the rolling oil can be affected by metal dust generated during the process and by external environmental factors (such as seasonal changes and humidity fluctuations). This can affect both the quality of the finished product and the effectiveness of the rolling machine's filtration system in removing impurities.

Some technologies have proposed improvements to the composition of metalworking fluids or oil-water separation devices, but these are difficult to apply to pure oil rolling equipment.

The present invention aims to provide a method and system for monitoring the quality of pure oil metalworking fluids, which can be used to monitor the quality of pure oil metalworking fluids in rolling equipment and further initiate control measures to improve relevant processing parameters to maintain rolling quality and enhance rolling efficiency.

To achieve the above-mentioned objectives, the present invention provides a method for monitoring the quality of pure oil-based metalworking fluids. This method for monitoring the quality of pure oil-based metalworking fluids includes the following steps. First, a sampling step is performed, in which a sample is obtained by sampling the metalworking fluid circulating in the rolling equipment. Next, a moisture content analysis step is performed on the sample to obtain a moisture content test value of the sample. Subsequently, a judgment step is performed, in which the moisture content test value of the sample is compared with the control range to generate a corresponding judgment result. Then, a control step is performed based on the judgment result. When the sample's moisture content is greater than a control range, the control step includes adding a first polar additive to the metalworking fluid and/or discharging at least a portion of the metalworking fluid. When the sample's moisture content is less than a control range, the control step includes adding a second polar additive to the metalworking fluid, wherein the second polar additive includes a first polar additive and water. When the sample's moisture content is within the control range, the control step includes performing a maintenance operation.

In one embodiment of the present invention, when the moisture content of the sample is less than 250 ppm, the regulating step includes adding a second polar additive.

In one embodiment of the present invention, when the moisture content of the sample is detected to be between 251ppm and 350ppm, the control step is performed to maintain the operation.

In one embodiment of the present invention, when the moisture content of the sample is detected between 251 ppm and (251+251*20%) ppm, the regulating step includes adding a first polar additive; when the moisture content of the sample is detected between (350-350*20%) ppm and 350 ppm, the regulating step includes adding a second polar additive.

In one embodiment of the present invention, when the sample's moisture content is detected to be between 351 ppm and 650 ppm, the control step includes discharging a portion of the used metalworking fluid and replenishing it with new metalworking fluid (including unused fresh oil, recycled oil after appropriate treatment of the used metalworking fluid, etc.), while also adding a first polar additive.

In one embodiment of the present invention, when the water content of the sample is greater than 651 ppm, the control step includes draining all used metalworking fluid and replenishing new metalworking fluid (including unused fresh oil, recycled oil after appropriate treatment of used metalworking fluid, etc.).

In one embodiment of the present invention, the new metalworking fluid is produced by distilling used metalworking fluid and removing water and impurities.

In one embodiment of the present invention, the above-mentioned regulating step further includes scraping off the floating oil on the metalworking fluid and/or increasing the activation rate of the filtering system of the rolling equipment.

In one embodiment of the present invention, the above-mentioned quality monitoring method further includes correlating the control range with the surface quality of the rolled plate, wherein the evaluation indicators of the surface quality of the rolled plate include the surface tension, contact angle, residual oil rate and/or friction coefficient of the metalworking fluid.

In order to achieve the above-mentioned purpose, the present invention also provides a quality monitoring system for pure oil-type metalworking fluid. This quality monitoring system is configured to be connected to the rolling equipment and perform the above-mentioned quality monitoring method. The quality monitoring system includes a sampling device, a moisture content analyzer, and a processing control unit. The sampling device is configured to sample the metalworking fluid circulating in the rolling equipment to obtain a sample. The moisture content analyzer is configured to perform moisture content analysis on the sample to obtain a moisture content detection value of the sample. The processing control unit signal is connected to the moisture content analyzer and is configured to perform a judgment step and a control step.

As described above, the pure oil-based metalworking fluid quality monitoring method and system provided by the present invention are particularly suitable for pure oil-based rolling mill equipment. The system primarily monitors the operation and quality of the rolling mill equipment based on the water content of the metalworking fluid. Furthermore, corresponding control and improvement measures are provided based on different water content detection values to maintain the lubrication and rolling quality of the metalworking fluid, thereby extending the service life of the rolling mill equipment and improving its efficiency.

To make the above and other objects, features, and advantages of the present invention more readily apparent, the following describes preferred embodiments of the present invention in detail with reference to the accompanying drawings. Furthermore, directional terms used herein, such as up, down, top, bottom, front, back, left, right, inside, outside, side, periphery, center, horizontal, transverse, vertical, longitudinal, axial, radial, topmost, or bottommost, are intended solely for reference purposes with respect to the accompanying drawings. Therefore, these directional terms are intended to facilitate explanation and understanding of the present invention and are not intended to limit the present invention.

Please refer to Figures 1 and 2, which are schematic diagrams of a quality monitoring method and a quality monitoring system for a pure oil-type metalworking fluid according to an embodiment of the present invention, respectively. The quality monitoring method S1 of this embodiment can be mainly performed using the quality monitoring system 2. Specifically, the quality monitoring system 2 is connected to the rolling equipment A, and can sample and analyze the water content of the metalworking fluid circulating in the rolling equipment A as an evaluation indicator of the metal wear of the plastic working contact area between the delay roller and the rolling plate and the surface quality of the rolling plate (such as roughness), so as to further adjust the water content of the metalworking fluid to keep it within the control range, which is beneficial to improving the rolling efficiency and the surface quality of the rolling plate. In this embodiment, the metalworking fluid may include rolling oil and lubricating oil. Furthermore, the quality monitoring method S1 and quality monitoring system 2 of this embodiment can be applied to hot rolling or cold rolling lubrication processes for rolling or plastic working of metals such as steel, copper, aluminum, and alloy steel, to ensure the surface quality of the rolled sheet after completion.

As shown in Figure 1, the quality monitoring method S1 of this embodiment includes a sampling step S11, a moisture content analysis step S12, a determination step S13, and a control step S14. As shown in Figure 2, the quality monitoring system 2 of this embodiment includes a sampling device 21, a moisture content analyzer 22, and a processing control unit 23. In the sampling step S11, the metalworking fluid circulating in the rolling equipment A is sampled by the sampling device 21 to obtain a sample S. Specifically, a bypass line (by pass) can be installed at an appropriate location in the metalworking fluid circulation route in the rolling equipment A to connect to the sampling device 21, thereby facilitating the sampling device 21 to obtain the sample S. In the moisture content analysis step S12, the moisture content of the sample S is analyzed by the moisture content analyzer 22 to obtain the moisture content test value of the sample. In one embodiment, the moisture content analyzer 22 can be set near the sampling device 21.

In the judgment step S13, the processing control unit 23 compares the moisture content of the sample S with the control range to generate a corresponding judgment result. In the control step S14, the processing control unit 23 controls the moisture content of the metalworking fluid based on the judgment result. Specifically, the processing control unit 23 is signal-connected to the moisture content analyzer 22. The processing control unit 23 can determine the surface quality of the rolled sheet based on the moisture content of the sample S and further control the moisture content of the metalworking fluid based on the judgment result. When the measured moisture content of sample S is greater than the control range, the processing control unit 23 may perform a control step, such as adding a first polar additive to the metalworking fluid and/or draining at least a portion of the metalworking fluid, to maintain an appropriate moisture content in the metalworking fluid. When the measured moisture content of sample S is less than the control range, the processing control unit 23 may perform a control step, such as adding a second polar additive to the metalworking fluid, to maintain an appropriate moisture content in the metalworking fluid. When the measured moisture content of sample S falls within the control range, the processing control unit 23 may perform a maintenance operation, i.e., not adding the first polar additive or the second polar additive. In this embodiment, the second polar additive includes the first polar additive and water (e.g., deionized water). By utilizing the appropriate compatibility between polar additives and water, the water content of metalworking fluids can be controlled.

In this embodiment, the process control unit 23 has a built-in relationship table (as shown in Table 1 below) correlating the measured moisture content of the metalworking fluid with the surface quality of the rolled sheet. Therefore, the process control unit 23 can determine the surface quality of the rolled sheet based on the measured moisture content and further adjust the moisture content of the metalworking fluid based on the determination result. As shown in Table 1, when the moisture content of sample S is between 251ppm and 350ppm, the surface quality of the rolled plate is judged to be the first level, which is good. When the moisture content of sample S is between 151ppm and 250ppm or 351ppm and 450ppm, the surface quality of the rolled plate is judged to be the second level, which is the second best. When the moisture content of sample S is less than 150ppm (for example, 51ppm and 150ppm or less than or equal to 50ppm), the surface quality of the rolled plate is judged to be the second level, which is the second best. ) or when it is between 451ppm and 550ppm, the surface quality of the rolled plate is judged to be the third level; when the moisture content of sample S is between 551ppm and 650ppm, the surface quality of the rolled plate is judged to be the fourth level; when the moisture content of sample S is greater than or equal to 651ppm, the surface quality of the rolled plate is judged to be the worst level 5. Table 1: Relationship between moisture content and surface quality of rolled plate Quality level 3 3 2 1 2 3 4 5 Moisture content (ppm) Control range ≦50 51~150 151~250 251~350 351~450 451~550 551~650 ≥651

In this embodiment, a relationship table between moisture content and rolled plate surface quality is established based on evaluation indicators such as surface tension, contact angle, residual oil rate, and/or friction coefficient of metalworking fluids. Specifically, this disclosure analyzes the surface tension, contact angle, residual oil rate, and friction coefficient of oil samples with varying moisture contents (e.g., Oils A through E in Table 2). As shown in Table 2, the surface tension values of the oil samples are inversely proportional to the moisture content; the friction coefficient values of the oil samples decrease and then increase with increasing moisture content; the contact angle values of the oil samples decrease and then increase with increasing moisture content; and the residual oil rate values of the oil samples are directly proportional to the moisture content. Since a small contact angle facilitates the penetration of machining oil into the contact area between the workpiece and the tool to reduce friction and wear, and also exerts a moistening effect, a higher residual oil rate also increases the probability of oil spots being found on the surface of the workpiece after annealing. Therefore, based on the oil sample quality performance test values and water content trends in Table 2, it can be concluded that Oil C can take into account both rolling quality performance and rolled plate surface quality. Table 2: Quality performance evaluation of oil samples with different water contents A oil B oil C oil D oil E oil Moisture content (ppm) ≦100 200 300 500 1000 Surface tension (mN/m) 26.3 26.2 26.2 26.2 26.1 Contact angle (.) 10.47 9.73 8.45 8.51 8.96 Residual oil rate (%) 0.03 0.04 0.04 0.05 0.07 Friction coefficient (μ) 0.0998 0.0836 0.0801 0.0868 0.1154

After the process control unit 23 determines the surface quality of the rolled sheet based on the moisture content values in Table 1, for example, it can further adjust the moisture content of the metalworking fluid based on the determination result. In a specific example, when the moisture content of sample S is less than 250 ppm, the process control unit 23 can determine that the surface quality of the rolled sheet is at the second or third level. At this point, a second polar additive can be added to increase the moisture content of the metalworking fluid.

In another specific example, when the moisture content of sample S is detected to be between 251ppm and 350ppm, the processing control unit 23 can determine that the quality of the rolling plate surface is the first level (optimal level), so it can perform a maintenance operation, that is, maintain the original setting parameters without adding the first polar additive or the second polar additive. In some application cases, when the quality requirements for the rolled plate surface are relatively high, the processing control unit 23 may also perform an adjustment operation when the moisture content detection value of the sample S is within the range of 251ppm~350ppm but close to the end value. For example, a first polar additive is added when the moisture content detection value of the sample S is 251ppm~(251+251*20%)ppm; a second polar additive is added when the moisture content detection value of the sample S is (350-350*20%)ppm~350ppm, so as to maintain a better moisture content of the metalworking fluid.

In another specific example, when the moisture content of sample S is detected to be 351ppm~650ppm, the processing control unit 23 can control the used metalworking fluid discharged from the rolling equipment A and replenish new metalworking fluid, while adding a first polar additive to reduce the moisture content of the metalworking fluid. For example, when the moisture content of sample S is between 351ppm and 450ppm, the processing control unit 23 can determine that the quality of the rolled plate surface is the second level. At this time, the processing control unit 23 can control the rolling equipment A to drain 35% of the used metalworking fluid and replenish an equal amount of new metalworking fluid while adding the first polar additive. When the moisture content of sample S is between 451ppm and 550ppm, the processing control unit 23 can determine that the quality of the rolled plate surface is the third level. At this time, the processing control unit 23 can control the rolling equipment A to drain 35% of the used metalworking fluid and replenish an equal amount of new metalworking fluid while adding the first polar additive. The processing control unit 23 can control rolling equipment A to drain 50% of the used metalworking fluid and replenish it with an equal amount of new metalworking fluid, while also adding a first polar additive. When the moisture content of sample S is between 551ppm and 650ppm, the processing control unit 23 can determine that the surface quality of the rolled plate is Grade 4. At this point, the processing control unit 23 can control rolling equipment A to drain 70% of the used metalworking fluid and replenish it with an equal amount of new metalworking fluid, while also adding the first polar additive. In this embodiment, the new metalworking fluid is produced from used metalworking fluid after appropriate treatment (e.g., distillation and removal of moisture and impurities), thereby achieving the environmentally friendly goal of reusing used oil. In other embodiments, the new metalworking fluid can also be fresh, unused oil. In some embodiments, the processing control unit 23 can also control the filtering system of the rolling equipment A to increase the operating rate by 30%, 50% or 75% according to the quality level of the rolled plate surface it determines, or can perform an oil scraping operation on the metalworking fluid.

In another specific example, when the moisture content of sample S is greater than 651 ppm, the process control unit 23 may control rolling apparatus A to drain the used metalworking fluid and direct the used metalworking fluid into a separator to remove moisture and impurities before reusing it as fresh metalworking fluid. In some embodiments, before draining the used metalworking fluid, the process control unit 23 may first obtain information about the surface quality of rolling apparatus A to assess whether draining is necessary, thereby avoiding the time and cost of draining operations caused by misjudgments. In some embodiments, the processing control unit 23 may also issue an abnormal alarm within a preset control range based on the operator's settings to remind the operator to perform actions such as changing operating setting parameters, replacing the filter material of the filter system of the rolling device A, or starting a backwash operation of the filter system.

As can be seen from the embodiments of the present invention, the quality monitoring method and system for pure oil-based metalworking fluids provided by the present invention are particularly suitable for pure oil-based rolling equipment. The system primarily monitors the operation and quality status of the rolling equipment based on the water content of the metalworking fluid, and then provides corresponding control and improvement measures based on different water content detection values to maintain the lubrication and rolling quality of the metalworking fluid, extend the service life of the rolling equipment, and improve the efficiency of the rolling equipment.

Although the present invention has been disclosed with reference to preferred embodiments, this is not intended to limit the present invention. Anyone skilled in the art may make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope of the attached patent application.

S1: Quality Monitoring Method S11: Sampling Step S12: Moisture Content Analysis Step S13: Judgment Step S14: Control Step 2: Quality Monitoring System 21: Sampling Equipment 22: Moisture Content Analyzer 23: Processing Control Unit A: Rolling Equipment S: Sample

Figure 1 is a schematic flow diagram of a method for monitoring the quality of a pure oil-based metalworking fluid according to an embodiment of the present invention. Figure 2 is a schematic diagram of a system for monitoring the quality of a pure oil-based metalworking fluid according to an embodiment of the present invention.

S1: Quality Monitoring Methods

S11: Sampling step

S12: Moisture content analysis step

S13: Judgment Step

S14: Control Steps

Claims (10)

A method for monitoring the quality of a pure oil-based metalworking fluid comprises: Sampling the metalworking fluid circulating in a rolling mill to obtain a sample; Analyzing the sample to obtain a moisture content value; Comparing the moisture content value of the sample with a control range to generate a corresponding determination result; Controlling the sample based on the determination result, wherein: When the measured water content of the sample exceeds the control range, the adjusting step includes adding a first polar additive to the metalworking fluid and/or draining at least a portion of the metalworking fluid. When the measured water content of the sample falls below the control range, the adjusting step includes adding a second polar additive to the metalworking fluid, wherein the second polar additive comprises the first polar additive and water. When the measured water content of the sample falls within the control range, the adjusting step includes performing a maintenance operation. The quality monitoring method for a pure oil-type metalworking fluid as described in claim 1, wherein when the water content of the sample is less than 250 ppm, the adjustment step includes adding the second polar additive. The method for monitoring the quality of a pure oil-based metalworking fluid as described in claim 1, wherein the control step performs the maintenance operation when the water content of the sample is detected to be between 251 ppm and 350 ppm. The method for quality monitoring of a pure oil-based metalworking fluid as described in claim 3, wherein when the water content of the sample is detected to be between 251 ppm and (251 + 251 * 20%) ppm, the control step comprises adding the first polar additive; and when the water content of the sample is detected to be between (350 - 350 * 20%) ppm and 350 ppm, the control step comprises adding the second polar additive. The method for monitoring the quality of a pure oil-based metalworking fluid as described in claim 1, wherein when the water content of the sample is detected to be between 351 ppm and 650 ppm, the control step includes: discharging a portion of the used metalworking fluid and replenishing the fluid with new metalworking fluid, while simultaneously adding the first polar additive. The method for monitoring the quality of a pure oil-based metalworking fluid as described in claim 1, wherein when the water content of the sample is greater than 651 ppm, the control step includes: draining all used metalworking fluid and replenishing new metalworking fluid. A method for monitoring the quality of a pure oil-type metalworking fluid as described in claim 5 or 6, wherein the new metalworking fluid is produced by distilling and removing water and impurities from the used metalworking fluid. In the method for monitoring the quality of a pure oil-type metalworking fluid as described in claim 5 or 6, the control step further includes scraping off floating oil on the metalworking fluid and/or increasing the activation rate of the filtration system of the rolling equipment. The method for quality monitoring of a pure oil-type metalworking fluid as described in claim 1 further includes correlating the control range with the surface quality of a rolling plate, wherein the evaluation indicators of the surface quality of the rolling plate include the surface tension, contact angle, residual oil rate and/or friction coefficient of the metalworking fluid. A quality monitoring system for pure oil-based metalworking fluid is configured to be connected to a rolling mill and to perform the quality monitoring method described in any one of claims 1 to 9. The quality monitoring system comprises: a sampling device configured to sample the metalworking fluid circulating in the rolling mill to obtain the sample; a moisture analyzer configured to analyze the sample to obtain a moisture content value; and a processing control unit signal-connected to the moisture analyzer and configured to perform the determination step and the control step.