[0001] The present invention is generally related to coolant delivery systems in CNC machines. More particularly, the present invention is related to a method and system of flow of coolant in ‘Gang tooling’ type of CNC lathe machines.

BACKGROUND OF THE INVENTION

[0002] CNC lathe machines are widely used for manufacturing parts or components, since these machines automate the manufacturing process by implementing computer generated design and directives. Minimizing the human control and supervision, CNC machines are faster and efficient to use. To execute more than one tooling functions in a CNC lathe machine,‘gang tooling’ methods are being utilized; where multiple tools are mounted on toolplate, mounted on the cross slide. Continuous working of the tools produces heat that may hamper the tool productivity and life, and also part quality. Hence, coolant delivery systems are also equipped with the gang tooling on CNC lathe machines to cool off the working zones. Another advantage of delivering a coolant around the working zones is chip removal and reducing any complications occurring from chip clogging. [0003] Various methods are developed to have efficient coolant delivery systems. Some conventional methods adopt a slant bed for CNC gang tool lathe, where the slant bed encourages efficient chip removal and coolant flow. While in another technologies, the machines use a distributor to direct coolant from pump to all the blocks in the gang tool. In such cases, the flow rate and pressure of the coolant gets distributed among the number of blocks present in the gang tool. For an example, if in a gang tooling method, the number of blocks are 5 and the pump flow rate is 20 litres per minute, then flow through each block would be 20/5 = 4 litres/minute. Hence, using a distributor reduces the flow rate and pressure of the coolant, each block would experience simultaneously. Further, employing this technology for coolant delivery, all the tool blocks in the gang tooling receive coolant simultaneously. Resultantly, when one tool is performing a machining operation, the coolant from other blocks may escape from a machine enclosure and may get sprayed all around creating a mist. This causes wastage of coolant and may also cause environmental hazards.

[0004] Other conventional methods of applying a coolant in the CNC lathe machines involve using a jet stream or using high pressure coolant systems. However, present technologies fail to solve the problems of wastage of coolant and providing full coolant flow rate and pressure as is originated from the pump only.

SUMMARY OF THE INVENTION [0005] Hence, it is an objective of the present invention to provide a coolant delivery system in the gang tooling methods for CNC lathe machines that ensures full flow rate and pressure of coolant. [0006] It is an objective of the present invention to provide the coolant delivery system that keeps a check on the wastage of the coolant and minimizes or negates the wastage fully in the gang tooling methods. [0007] It is also an objective of the present invention to provide a smart coolant delivery device that delivers the coolant to that tool only which is called by CNC program to perform its operation, while guaranteeing full flow rate and pressure to the operating tool.

[0008] It is a further objective of the present invention to prevent chip clogging in external pipes and hence, maintain no leakage that may occur due to cuts in pipes from the chips.

[0009] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0010] FIG. 1A illustrates a system of CNC manufacturing process including a CNC lathe gang tool equipped with a smart coolant delivery system, in accordance with an embodiment of the present invention; and [0011] FIG. 2 shows a flow chart illustrating a cooling method implemented in a manufacturing process using a CNC lathe gang tool with a smart coolant delivery system, in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] This patent describes the subject matter for patenting with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. The principles described herein may be embodied in many different forms.

[0013] Illustrative embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0014] The present invention discloses a smart coolant delivery system in ‘gang tooling’ methods for CNC lathe machines. The coolant delivery system is operated by a programmable logic control (abbreviated as PLC) which is executed by a CNC controller. The delivery system comprises a control valve associated to each tool equipped in the gang tooling. The valves control the flow of coolant to the tools and are actuated by the PLC. Whenever a tool is signaled to be operated, by the CNC controller, the valve associated with the tool also gets activated by the logic. This in turn, allows the coolant to flow through the valve via a tool base plate and reaches the tool working zone/site. The coolant cools off the working zone. The coolant delivery system ensures that the coolant reaches to that tool only which is operating currently. Such activating of the particular valve for the particular operating tool only employs full flow rate and pressure of coolant pump to deliver the coolant to the currently operating tool.

[0015] FIG. 1 illustrates an exemplary environment including a smart coolant delivery system for CNC manufacturing process including a CNC lathe gang tool , in accordance with an embodiment of the present invention. The environment 100 includes of a side of CNC lathe gang tools working zones 102 and a side of the smart coolant delivery system 104. As shown in an exemplary system in FIG. 1, the gang tool side 102 may have 8 operational tools 106, each with a corresponding tool block (T1-T8), mounted over a tool base plate 108. Therefore, each tool 106 has its own tool block T1-T8; tools are labeled same in the FIG. 1 for ease of description. It is apparent, that the tools 106 may/may not be different with each other, as used in gang tooling for

CNC lathe. Further, the coolant delivery system 104 comprises a coolant main line 110, a coolant channel 112, 8 control valves (V1-V8), 8 coolant connecting lines (C1-C8) that connect the control valves with the tools blocks, and coolant flow lines 114 for delivering the coolant to the tool working zones. The coolant main line 110 provides the coolant to the coolant delivery system 104, whereas the coolant channel 112 channelizes the coolant to each valve (VI -V8).

Every tool block (T1-T8) is connected with its own control valve (V1-V8) via a corresponding coolant connecting line (C1-C8). This means the environment 100 has an equal number of tools and tool blocks associated with an equal number of control valves. It may be apparent to a person skilled in the art that the coolant delivery system 102 may have more or less than 8 control valves and tool blocks, depending/not depending on the number of gang tools in the CNC lathe, without deviating from the meaning and scope of the present invention. It may be also apparent by a person skilled in the art that the exemplary environment 100 may have a different number of tool blocks and control valves and not necessarily being equal, depending on the design and requirement of the system, without deviating from the meaning and scope of the present invention. [0016] The control valves (V1-V8) open and close the coolant connecting lines (C1-C8) to allow or prevent the coolant from flowing to the tool blocks (T1-T8). The coolant flow lines 114 deliver the coolant to discharge from the required tool block (T1-T8) and eventually reach the required tool 106 working zones for cooling them off. [0017] The coolant delivery system 104 is controlled by a PLC logic executed by a CNC controller (not shown in the FIG. 1). The CNC controller, executing pre-programmed sequences of machine control commands, also automates the operation of the tools 106. In an embodiment, the environment 100 may employ two different PLC logics, which are working together, to control the operations of the tools and the control valves individually, depending on the requirement and design of the manufacturing process, without deviating from the meaning and scope of the present invention. [0018] While in operation, the PLC logic instructs a particular tool to be operated as and when required during a manufacturing process. When a particular tool 106 is commanded by the CNC controller to be operated, the PLC logic actuates the valve linked with that particular tool simultaneously. This instructs the linked valve (one from V1-V8) to open up and allows the coolant to flow through the corresponding coolant connecting line (one from C1-C8) that connects the tool block ( one from T1-T8) and the associated valve (one from V1-V8). Thereafter, the coolant flow through the coolant flow line 114 inside the tool base plate 108 and emerges out from the designated tool block (required one from T1-T8) in order to reach the currently operating tool working zone.

[0019] Considering an exemplary situation for a clear understanding, assume the second tool 106 with the corresponding tool block T2 is required to be operated in the manufacturing process. The PLC logic calls the second tool 106 and command for its operation. Simultaneously, the logic also activates the control valve V2 linked with the second tool. This, in turn, opens up the control valve V2, which further opens up the coolant connecting line C2 between the tool block T2 and the control valve V2. Hence, the coolant flows from the coolant channel 112 to the control valve V2 that allows it to further flow via the coolant connecting line C2; then flowing via the coolant flow line 114, which is inside the tool base plate 108, emerges from the designated tool block T2 and eventually reaches the working zone of second tool 106. [0020] Directing the flow of coolant by implementing the present coolant delivery system 104, allows the coolant to flow through the channels which are inside the tool base plate 108, hence avoiding the flow through any external pipes. Further, the delivery system 104 ensures that the coolant flows only to that tool which is called by the PLC logic for operation; by actuating the control valve which is linked with that tool, while de-activating the rest of the control valves.

[0021] The coolant delivery system 104 uses any fluid that effectively reduces the temperature of the tool working zone/site. In an embodiment of the present invention, the coolant is high- pressured stream of air. In another embodiment, the coolant is any cool liquid that reduces the temperature, such as cold water, or may be other suitable liquid coolant. The coolant may also depend on the type of tools used in the gang tooling.

[0022] It may be apparent by a person skilled in the art, that the process 100 may employ operation of two or more tools simultaneously, while also actuating the corresponding two or more control valves, depending on the requirement of the manufacturing process, without deviating from the meaning and scope of the present invention. It may be apparent by a person skilled in the art that the coolant delivery system 104 may also be installed with any other CNC machine, depending on the workability of the coolant delivery system 104 with the CNC machine in question, without deviating from the meaning and scope of the present invention.

[0023] FIG. 2 shows a flow chart illustrating a coolant delivery method implemented in a manufacturing process using a CNC lathe gang tool with a smart coolant delivery system, in accordance with an embodiment of the present invention. In the manufacturing process, a CNC controller controls the operation of the tools, by executing a PLC logic which includes a programmed sequence of machine control commands. In the method 200 according to the FIG. 2, the CNC controller instructs a required tool to start its operation, as and when required in the manufacturing process, at step 202. The CNC lathe gang tools 106 is equipped with the smart coolant delivery system 104, which further comprises a number of control valves corresponding to the number of tool blocks mounted on a tool base plate in the CNC lathe machine. After commanding the required tool to operate, the controller, running the PLC logic, also actuates a control valve that is linked with that tool only, at step 204. [0024] The control valves are connected with their corresponding tool blocks via a number of coolant connecting lines to allow flow of coolant. Therefore, when the linked control valve activates at step 204, it further allows the corresponding coolant connecting line to open up a channel for the coolant to flow from the linked control valve to the particular operating tool block, at step 206. Thereafter, the coolant flows through a coolant flow line which is inside the tool base plate 108, at step 208. Consequently, the coolant discharges from the designated tool block T1-T8, to finally reach the operating tool site, at step 210. Adopting this method, the control valve ensures flow of coolant to the required tool only which is in operation. Further, providing full flow rate and pressure of coolant to that tool only, without compromising with the flow rate and pressure.

[0025] Advantageously, the present invention provides a smartly controlled coolant delivery system that comprises actuating control valves associated with gang tools, as and when required, to allow flow of coolant. Adopting the present invention and activating only that control valve which is linked with the tool under operation, to allow the delivery of the coolant only to the operating tool, ensures full flow rate and pressure of pump to deliver the coolant to that particular operating tool. This effectively results in increasing the tool life & increasing machining parameters. Further, in case of using drills as one of the tools, the present invention prevents pre-mature failure of the drills which may be caused by chip clogging; where chip clogging may happen due to inadequate coolant pressure and flow rate. This further means by implementing the present invention, full flow rate and pressure of the coolant also helps in removing chip clogging. Also, since the coolant is delivered to the tools through internal channels only and avoiding any external pipes, there is no collection of chips in the pipes and hence, no leakage that may happen through cuts in the external pipes.

[0026] Furthermore, since the present invention allows flow of coolant to only operating tool, this also prevents wastage of coolant as no coolant can come out of non-operational blocks and hence, no mist is formed.

[0027] The smart coolant delivery system also enables use of high pressure coolant in gang tooling machines to achieve very high machining parameters and allowing breaking of chips into small pieces. Whereas, high pressure coolant cannot be used in the conventional coolant delivery systems due dissipation of pressure through multiple outlets in multiple blocks. Further, the present invention enables use of‘through coolant’ tools, such as drills on gang tooling machines. Since‘through coolant’ tools need coolant to be delivered only through them as they have narrow orifices and if coolant is also flowing from nearby blocks (which have bigger holes) then most of the coolant will drain away from bigger holes and‘through coolant’ tools may fail. But in this present invention, the coolant flows through internal channels to the exact tool required, and avoid flowing to other tools which may have bigger holes. [0028] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the present disclosure. Indeed, the novel methods, devices, and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the methods, devices, and systems described herein may be made without departing from the spirit of the present disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the present disclosure.

[0029] The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. [0030] Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.

[0031] Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims.