Environmentally-friendly machining through innovation
UltraMQL is a hybrid stream-generator/ultrasonic-transducer aerosoliser that responds and adapts to viscosity changes, and provides real-time monitoring of the lubrication process. In addition, a remote monitoring solution, using acoustic and video monitoring, provides workshops with a fully integrated retrofit approach to sustainable high-tech manufacturing.
Environmentally-friendly machining through innovation
UltraMQL is a hybrid stream-generator/ultrasonic-transducer aerosoliser that responds and adapts to viscosity changes, and provides real-time monitoring of the lubrication process. In addition, a remote monitoring solution, using acoustic and video monitoring, provides workshops with a fully integrated retrofit approach to sustainable high-tech manufacturing.
Concept and System
Concept and SystemThe use of ultrasonic vibration for creating the aerosol would reduce the influence of different lubricant viscosity on flow rates reducing the need for calibration and adjustment from the operator. An electrostatic charge generator will be used to charge the oil droplets facilitating their transport toward the work-piece (as similarly charged droplets would electrostatically repeal from each other preventing coalescence) and facilitating their adhesion where the lubricant is needed (the work piece is generally electrically connected to the machine bed, which is electrically grounded).
It will include an IoT remote monitoring capability to allow the operator to monitor several key process parameters remotely on a tablet or smartphone and receive an alarm when they deviate from the allowed tolerances: a simplified acoustic monitoring system coupled with a camera kept clean through using an oleophobic optic in front of the lens, to continuously monitor the cutting; oil level warnings to reduce the risk of running a dry cut; an optional remotely operated emergency stop to allow the operator to immediately stop the manufacturing in the case of need.
Concept and System
Concept and SystemThe use of ultrasonic vibration for creating the aerosol would reduce the influence of different lubricant viscosity on flow rates reducing the need for calibration and adjustment from the operator. An electrostatic charge generator will be used to charge the oil droplets facilitating their transport toward the work-piece (as similarly charged droplets would electrostatically repeal from each other preventing coalescence) and facilitating their adhesion where the lubricant is needed (the work piece is generally electrically connected to the machine bed, which is electrically grounded).
It will include an IoT remote monitoring capability to allow the operator to monitor several key process parameters remotely on a tablet or smartphone and receive an alarm when they deviate from the allowed tolerances: a simplified acoustic monitoring system coupled with a camera kept clean through using an oleophobic optic in front of the lens, to continuously monitor the cutting; oil level warnings to reduce the risk of running a dry cut; an optional remotely operated emergency stop to allow the operator to immediately stop the manufacturing in the case of need.
Benefits of such system could be envisaged as follows:
Clean manufacturing (not requiring significant cleaning post manufacture)
Greatly increased tool life or material removal rate/productivity
Possibility to use different oil grades and even carriers for solid lubricants
Portable – easy to modernise old workshops and shift between machines
Possibility to reduce the escape of aerosol in the workshop and improve the air quality compared to flood or high pressure coolants
IoT based system control
Based on the parameters calculated by University of Brighton, an IoT based system will be developed with remote monitoring and control. Such system will benefit in number of ways i.e. little to no calibration required when machining a range of material, increased interoperability and productivity, energy efficiency and reduced process risks.
In addition, the system will allow a network of the UltraMQL fitted devices to collaborate in an ‘Internet of Digital Twins’ to allow equipment health monitoring across the network, business level consumables ordering and closed loop quality monitoring of the final product.
Finally, the solution will be delivered across multiple platforms including augmented and virtual and tablet systems enabling both on-site and remote users to address issues as quickly as possible and reduce down-time.
Improved lubricant atomiser system
Power Ultrasonic (Development of piezo-ceramic driven high-frequency sonotrodes in high-durability materials (Stainless Steel: 20kHz-25kHz. Ti6-4: 25kHz-30kHz and Aluminium: 25kHz-40kHz) will help in breaking lubricant droplets (300-500 um) into molecular-sized mist (5-10 um) to facilitate penetration in the interface between the work-piece and the tool aiming for an improved lubrication and machinability). Rapid reaction droplet stream generators would provide feedback and fine control on the flow rate of lubricant.
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Improved lubricant atomiser system
IoT based system control
Based on the parameters calculated by University of Brighton, an IoT based system will be developed with remote monitoring and control. Such system will benefit in number of ways i.e. little to no calibration required when machining a range of material, increased interoperability and productivity, energy efficiency and reduced process risks.
In addition, the system will allow a network of the UltraMQL fitted devices to collaborate in an ‘Internet of Digital Twins’ to allow equipment health monitoring across the network, business level consumables ordering and closed loop quality monitoring of the final product. Finally, the solution will be delivered across multiple platforms including augmented and virtual and tablet systems enabling both on-site and remote users to address issues as quickly as possible and reduce down-time.UltraMQL is a joint venture between leading experts in their fields.
Kugel Rotary are leaders in design, manufacture and supply of linear and rotary motion products and services. They will host testing the UltraMQL system in their facility (WP6) and lead exploitation and dissemination
Bloc Digital is a leading digital technology studio pioneering immersive and creative technologies to deliver cutting-edge digital data visualisation and have been leading the development of UltraMQL’s controls and software.
Quaker Houghton are global leaders in industrial process fluids and are building on their existing MQL expertise to identify and tailor make lubricants for performance improvement of the UltraMQL system.
The Nuclear Advanced Manufacturing Research Centre at the University of Sheffield are applying their expertise in manufacturing & machining to UltraMQL.
The University of Brighton bring 20+ years’ experience in aerosol and optical measurement research to support the design of UltaMQL’s atomisers.
UltraMQL is a joint venture between leading experts in their fields
Kugel Rotary are leaders in design, manufacture and supply of linear and rotary motion products and services. They will host testing the UltraMQL system in their facility (WP6) and lead exploitation and dissemination
Bloc Digital is a leading digital technology studio pioneering immersive and creative technologies to deliver cutting-edge digital data visualisation and have been leading the development of UltraMQL’s controls and software.
Quaker Houghton are global leaders in industrial process fluids and are building on their existing MQL expertise to identify and tailor make lubricants for performance improvement of the UltraMQL system.
The Nuclear Advanced Manufacturing Research Centre at the University of Sheffield are applying their expertise in manufacturing & machining to UltraMQL.
The University of Brighton bring 20+ years’ experience in aerosol and optical measurement research to support the design of UltaMQL’s atomisers.
Innovate UK are the UK’s innovation agency. We help UK businesses to grow through the development and commercialisation of new products, processes and services, supported by an outstanding innovation ecosystem that is agile, inclusive and easy to navigate. UltraMQL is funded and supported by Innovate UK via Smart grant Project No. 98833
Innovate UK are the UK’s innovation agency. We help UK businesses to grow through the development and commercialisation of new products, processes and services, supported by an outstanding innovation ecosystem that is agile, inclusive and easy to navigate. UltraMQL is funded and supported by Innovate UK via Smart grant Project No. 98833
For more information on UltraMQL, please contact:
info@ultramql.com
Copyright © 2023. All Rights Reserved.
For more information on UltraMQL, please contact:
info@ultramql.com
Copyright © 2023. All Rights Reserved.