DMG MORI Co. Ltd. introduces Adaptive Coolant Flow for optimized energy efficiency!
DMG MORI Co. Ltd. has unveiled Adaptive Coolant Flow, an advanced coolant management solution designed to automatically regulate high-pressure coolant flow during machining. The system aims to reduce energy consumption and CO₂ emissions while maintaining machining performance, tool life and surface finish quality.
In conventional machining environments, high-pressure coolant systems typically operate at maximum pressure regardless of the cutting tool or application requirements. This default setting often leads to excessive coolant usage and unnecessary energy consumption. Adaptive Coolant Flow addresses this inefficiency by dynamically adjusting coolant flow based on the specific cutting tool and machining parameters.
The system combines intelligent software with a dedicated control unit installed directly on the coolant tank. The software continuously calculates the optimal flow rate required for the active machining process, while the hardware component regulates and executes the flow adjustments in real time. By tailoring coolant delivery to actual process needs, the solution minimizes waste without compromising cutting performance.
According to DMG MORI, the technology can reduce the energy consumption of high-pressure coolant pumps by more than 80 percent compared to conventional systems operating at constant maximum output. Despite the reduced energy usage, machining quality and tool longevity are maintained, ensuring that productivity levels remain stable.
The physical components of the Adaptive Coolant Flow system feature complex high-pressure piping structures that are manufactured using additive manufacturing. These components are produced on DMG MORI’s Lasertec 30 SLM platform, enabling geometries that would not be feasible with traditional machining methods. The compact, additively manufactured design allows for efficient integration of pressure and flow control mechanisms directly into the coolant tank assembly.
The system is equipped with built-in sensors that continuously monitor flow rate, pressure, coolant concentration and temperature. All operational data is displayed in real time through the Ergoline X interface integrated with the Celos X control system. This transparency enables operators to track performance metrics and optimize coolant usage further.
Beyond energy savings and emission reductions, Adaptive Coolant Flow also minimizes mist formation and coolant evaporation within the machining area. Reduced mist generation improves workplace conditions and lowers overall coolant consumption. Fewer refills and improved process stability support uninterrupted automated production, particularly during unmanned night shifts and weekend operations.
With increasing emphasis on sustainable manufacturing and operational efficiency, Adaptive Coolant Flow represents a step toward smarter resource management in metalworking processes. By combining intelligent software, sensor integration and additive manufacturing design, DMG MORI delivers a solution that enhances both environmental performance and machining productivity.
