How can coolant management be automated?
With HYDAC, coolant management in machine tools can be automated using intelligent sensor technology, automatic refill systems, filter systems and digital monitoring solutions – including complete documentation in accordance with TRGS 611.
Challenges in coolant management: interview with Philipp Götz
What are the current challenges in fluid management, what problems arise from manual coolant handling and how can they be avoided through automation? Our product manager Philipp Götz answers these questions, among others, in a short interview.
The dangers of an unbalanced coolant concentrationNegative effects on cost-effectiveness, availability, quality & health
Foaming
Foaming disrupts the operational process and costs you valuable time.
Odour formation
The resulting odour can have health consequences for staff due to irritation of the respiratory tract.
Skin irritation
Contact with coolant can cause skin irritations that can disrupt operational processes.
High consumption of coolant concentrate
In the event of excess concentration, more coolant concentrate is used than necessary. This results in avoidable expenditure.
Short coolant emulsion service life
An unstable coolant level can negatively affect the emulsion's service life. The result: high resource consumption and increased costs.
Reduced tool service life
A coolant concentration that is too low can lead to high wear. This results in a reduced tool service life and decreased component quality.
Solutions for automating your coolant managementFully automatic monitoring & control ensures an optimum coolant concentration at all times
With the HYDAC FCU 5000 and PCS solutions, coolant management can be automated. Both systems constantly monitor the concentration, the machine tool's tank level and consumption and automatically compensate for deviations by adding oil or water.
Our PCS can regulate up to 5 machines simultaneously and the FCU 5000 even up to 10 units simultaneously. All consumption and concentration data is clearly displayed on a digital dashboard – including automatic documentation in accordance with TRGS 611.
The result: up to 78% less time spent on fluid management, cost savings of up to 38% and a longer tool service life with a reduction in tool costs of up to 7.6 %. Our solutions also enable 100 per cent automated production without manual coolant processes.
Our coolant automation solutions at a glance
HYDAC PCS 2000
The Process Fluid Concentration Sensor (PCS) features simple integration: instead of fixed pipework, it is connected via flexible hoses. This enables quick installation without the need for complex structural measures. It simultaneously monitors and regulates the coolant concentration of up to five machine tools, reliably ensuring optimum process conditions.
HYDAC FCU 5000
The Fluid Control Unit (FCU 5000) is the right solution for larger production environments. It can automatically monitor and regulate the coolant supply for up to 10 machine tools. This means that it offers a central, high-performance unit for efficient fluid management in larger systems, forming the perfect basis for fully automated production.
More information on the HYDAC FCU 5000
Supplementary products for automating your fluid management
HYDAC Coolant FillerMobile system for refilling coolant
The HYDAC Coolant Filler is the flexible solution for topping up coolant right at the machine tool. The mobile system is equipped with a coolant oil drum, while the water supply is provided via an integrated hose. The machine can conveniently be filled with the previously selected or stored quantity of coolant at the optimum concentration via a dispensing nozzle.
The concentration values stored for each machine ensure that manual and error-prone calculations are no longer necessary. In addition, the integrated data transfer enables automated documentation of refilling processes – for maximum process reliability and transparency in fluid management.
HYDAC Coolant CleanerMobile coolant filtration unit
The HYDAC Coolant Cleaner is a mobile filtration unit that efficiently cleans machine tool tanks. It reliably removes particulate solid contamination via bag filter elements, helping to extend fluid service life and reduce fluid life cycle costs (LCC).
The system can be used flexibly – whether it's for filling tanks from an IBC, for temporary off-line filtration, for unfiltered emptying or for use in combination with automation technology for continuous fluid monitoring and concentration control.
Thanks to its portability, the Coolant Cleaner can quickly and easily be used on different machines to ensure optimum fluid quality and process reliability.
Dirk JeskeIndustry Manager for Machine Tools at HYDAC
With our automated coolant management system, our customers aren't just spared time-consuming manual checks, documentation and refilling. They also achieve their return on investment more quickly. Less time and effort, increased process reliability and noticeable cost benefits go hand in hand here and create the conditions for fully automated production.
FAQ – Frequently asked questions & answers on coolant management
Coolant concentration
How do you mix coolant correctly?
Coolants are usually prepared manually: the concentrate is mixed with water in the correct ratio. It's important to use the correct concentration – too low values lead to corrosion and too high to skin irritation and foaming. The classic method of checking is with a refractometer.
Refilling is semi-automated with the HYDAC Coolant Filler: the quantity and concentration are already stored in the system. This reduces the error rate, keeps the coolant quality stable and takes the burden off of operators.
The fully automatic HYDAC systems FCU 5000 and PCS 2000 ensure that several machines are supplied centrally. They do this by continuously monitoring the concentration and other parameters and automatically topping up if necessary.
The FCU 5000 and the PCS 2000 ensure optimum mixing of the concentrate in the water. This results in improved emulsion quality and lower concentrate consumption.
What is the optimum percentage of coolant? What is the optimum coolant concentration?
The optimum concentration depends on the machining process, the material and the type of coolant used. As a rule, the values are between 5 and 10 %. Too low a concentration favours germs, too high a concentration leads to unnecessary costs and possible skin irritation.
Instead of relying on manual checks, our automated systems for coolant management ensure a constant concentration – for greater process reliability and less time and effort.
Coolant monitoring & conditioning
How often does coolant need to be changed or checked?
Traditionally, coolant is changed at fixed intervals – usually every few months. In reality, however, the service life depends on factors such as temperature, bacterial contamination or the introduction of foreign oils.
- Manual: Checking with a refractometer or test strips, changing according to appearance or odour.
- Semi-automatic: The mobile HYDAC Coolant Cleaner cleans the coolant emulsion right at the machine, extending its service life.
- Fully automatic: With the HYDAC FCU 5000 and PCS, the condition of the coolant is constantly monitored. The system immediately detects deviations in concentration and automatically adjusts it, enabling condition-based coolant changes instead of interval-based coolant changes.
How long does coolant last?
The shelf life of coolants depends on conditioning and the environment. Without monitoring, a coolant can become unusable after just a few weeks. With regular maintenance and automated conditioning by HYDAC systems, the service life can be significantly extended, reducing costs and disposal costs.
What significance does automated fluid management have for automated production?
Continuous coolant monitoring is crucial for stable and efficient automated production. It ensures that the lubrication and cooling effect remains optimal, reduces tool wear and prevents unplanned machine downtimes. Time-consuming manual checking and refilling processes, which would otherwise considerably limit the degree of automation, are also eliminated.
With solutions such as the HYDAC Fluid Control Unit FCU 5000 and the Processfluid Concentration Sensor (PCS), coolants can be both reliably monitored and automatically topped up – for maximum process reliability, consistent quality and reduced operating costs.
Problems when using coolants
Why does coolant foam or smell unpleasant?
Common causes of these symptoms when handling coolants are
- Incorrect concentration
- Contamination from foreign oils
- Microbiological growth (bacteria or fungi)
The result: foaming, unpleasant odour and skin problems occuring on contact with the coolant emulsion.
The HYDAC Coolant Cleaner reduces particles, oil residues and germs in the coolant emulsion – for a longer service life and better working conditions.
The HYDAC FCU 5000 and PCS also detect deviations immediately and automatically adjust the parameters. Problems such as foaming or unpleasant odours are therefore prevented proactively instead of being remedied retrospectively.
Safety & handling coolant
What is important to note when handling coolants?
Clear rules apply when working with coolants: avoid skin contact, wear personal protective equipment, check concentrations regularly and comply with limit values (e.g. nitrite/nitrate). Compliance with legal regulations on occupational safety and the environment also plays a central role in fluid management.
HYDAC provides support with secure, documentable processes:
- Coolant Filler/Coolant Cleaner for safe coolant management on individual machines
- PCS 2000/FCU 5000 as centralised systems that continuously monitor all coolant parameters, document them in accordance with regulations and ensure compliance
