Revolutionizing heavy equipment manufacturing with digital fluid management

In the production of heavy equipment for construction, forestry, mining and other industries, a variety of metals are used based on the performance requirements of the end-use application. These metals can range from carbon alloys used for strength and structural integrity to lightweight metals like aluminum and stainless steel, which provide corrosion resistance. Managing these materials in different metalworking applications, such as rolling, bending, forging, milling, grinding and drilling, is key to the manufacturer’s overall efficiency and profitability.

The industrial process fluid that enables operation is critical to these metalworking applications. A particular metalworking operation is only as good as how well its process fluid, also known as “metalworking fluid,” is managed.

Metalworking fluids typically provide three main functions: lubrication to remove friction between a tool and the workpiece, cooling to remove generated heat, and/or flushing to remove metal chips and fines.

In the case of coolants, many are water-soluble and applied as emulsions with a particular ideal concentration. Because concentration can vary due to natural evaporation or discharge, careful monitoring is recommended. Not maintaining optimal fluid concentration can lead to various problems, such as overconsumption of coolant, tool breakages, part defects, corrosion and even health and safety issues.

Image courtesy of Quaker Houghton

Though heavy equipment manufacturers have automated many parts of their manufacturing process, often the monitoring of metalworking fluid is done manually via regular collection of samples that are either sent to a laboratory for further analysis or are tested at the point of use with simple instruments like a refractometer. The labor effort for sampling alone can be significant. By the time laboratory analysis is completed, system conditions have changed. Alternatively, if an analog refractometer is used, human error can be introduced. Even when readings are accurate, replenishing fluid is still necessary to correct the concentration, a process which is often done manually.