Industry 4.0 Compliant
Will-Fill is available in three variants depending on machine sump depth; detecting level fluctuations of 120, 220 or 520mm respectively.
- Measures seven parameters:
- 1. pH levels
- 2. Concentration of oil /water mix
- 3. EC (hardness of water)
- 4. Coolant temperature
- 5. Oil usage
- 6. Water usage
- 7. Coolant level
- Works with any metal working fluid
- Fills and re-fills automatically to the level and concentration set by you
- Calibrates the sensors to the connected metalworking fluid and water supply
- Online dashboard for offsite monitoring
- Records the consumption of metalworking emulsion and water,enabling accurate cost control
- Detects abnormal fluid levels indicating a malfunction or possible leakage
- Sends an email notification of every event
- Reduce tool wear
- No erosion or staining of workpiece
- Reduced MWF and water consumption
- Reduced coolant odours
- Reduced operator skin complaints
- Minimise machine downtime
- No need to employ outside companies to monitor pH, Brix, EC, Temp, etc.
- Increased productivity and profit
- HSE data capture compliance
- No manual mixing of oil & water
- Retrieval of historic data on MWF condition alerts.
Understandably, at most precision mechanical workshops the emphasis is on the production process; increasing “uptime”, minimising contact time and reducing waste are all intrinsic to a profitable operation. CNC machines and tooling are becoming ever more complex, with faster cycle times and ever improving accuracy, with checks in place to ensure tight tolerances and repeatability. But what about the coolant / emulsion / metalworking fluid
View metalworking fluid as a liquid tool and the implications from a failure are just as grave as a machine tool breakdown. Increased tool life, improved surface finishes, ability to hold tighter tolerances, less oil usage, reduced scrappage are all benefits from ensuring optimal coolant condition.
Will-Fill measures the emulsion mix, pH level, water hardness as well as oil and water consumption on an hourly basis if necessary. The device will automatically adjust the Brix as required. Importantly, notifications are sent if results fall outside of the set parameters. This is particularly important for companies running “Lights Out” machining or an automated line. As “uptime” values are crucial for profitability then any potential for “downtime” must be eliminated where possible.
With regular micro adjustments being made and with the coolant being agitated by the device continuously the life of the emulsion is being extended by three or four times. The optimum emulsion condition is being preserved and enabling companies to maintain tolerances down to microns indefinitely as well as reducing instances of rusting, bacteria build up and the requirement for complete sump clean outs.
Will-Fill is connected to a dashboard or multiple dashboards of those with a need for the data via a cloud based system. Notifications are sent to your laptop or mobile device enabling you to react to any anomalies 24hrs a day. The device itself lights up blue when it’s measuring, green when all values are correct and red when measurements fall outside of the given tolerances. The operator is kept informed continuously. The data is stored and in time the results can be aggregated and used to help make predictive, adaptive or corrective changes. This is especially relevant to those companies with an eye on Industry 4.0 methodology.
As Will Fill operates independently the need for human intervention is minimal; once installed and the relevant parameters are set it will continually monitor and where necessary adjust the emulsion mix 24/7.
The bottom line is, that the bottom line can be improved. Profitability is maximised where waste and consumption is reduced and time and output is improved.
Will-Fill, Remove The Element Of Doubt
Will-Fill can easily be integrated with an existing or new installation. Will-Fill can be started up in an empty or semi-full metalworking fluid container. A round 140-mm opening is sufficient. The Will-Fill upperstructure takes up little space – 200 x 200 x 500 mm (LWH) – making it easy to fit. There is also a wizard that accompanies start-up of the device so that no settings are forgotten, ensuring perfect operation.
Take the guess work out of the process
Will-Fill is a patented and innovative solution that equips metalworking machines with a unique add on. Will-Fill monitors, reports on and adjusts the condition and mix of the metal working fluid, taking the guess work out of the process and improving operator effectiveness.
Electrical connection: 220V 3A
Control/drive: 24V DC
Water connection: push-in coupling 16 mm hose Incoming water pressure range: 1 – 7 Bar
Oil connection: push-in coupling 10 mm hose Oil pump self-priming: < 6 m
Mixing capacity: ± 800 litres/hour
Wi-Fi: 2.4 GHz
RGB LED status
Alarm buzzer: 85 dB
Operating temperature: 5 – 45° C
Brix: 0 to 35
pH: 0 to 14
Temperature: -5 to 45° C
EC: 0.5 uS/cm to 200 mS/cm Water level: ± 5 mm
H2O consumption: ± 2 litres