Minimization of Health Risks Due to Metalworking Fluid Microbes and Biocides: An Optimal Control System using Microfiltration and Flow Cytometry

该赠款为开发自动化和具有成本效益的控制系统提供资金，以最大限度地减少金属加工液（MWF）系统中微生物和过度依赖杀菌剂造成的职业健康和安全风险。 首先，该研究旨在了解允许基于膜的微滤技术在不破坏化学完整性的情况下从无杀菌剂的MWFs中去除微生物和相关内毒素的机制。 该研究将研究MWF化学，膜运输和成分保留之间的相互作用。 其次，该研究将研究流式细胞术技术在MWFs中实时微生物检测的新应用。 该研究将评估在MWF应用中最大化流式细胞术性能的物理化学条件。 第三，将基于流式细胞术和微滤开发最佳控制系统。 该控制系统将利用人工智能方法在线动态预测所需的微生物去除率和最佳微滤操作参数。该控制系统旨在消除美国约120万工人的微生物健康风险。 该系统还将大大提高美国机床工业的竞争地位，减少对环境的影响，降低总的加工成本，并尽量减少MWF性能的变化，使污染物的去除和回收。 这些考虑因素越来越重要，因为国家一级的立法压力越来越大，迫使该行业解决与MWF应用相关的环境和健康风险（例如，EPA金属产品和机械规则和NIOSH推荐的MWF暴露标准）。 最近的研究还表明，MWF系统的总成本，包括采购，处置和维护，在加工中是显着的，在许多情况下，远远超过工具的成本。 由于从制造过程中去除MWF的技术困难，这些驱动因素将继续推动行业对无生物杀灭剂微生物控制系统和MWF回收的需求，以减少健康风险，成本，环境影响和性能变化。

This grant provides funding for the development of an automated and cost-effective control system to minimize occupational health and safety risks posed by microorganisms and excessive reliance on biocides in metalworking fluid (MWF) systems. First, the research aims to understand the mechanisms that permit membrane-based microfiltration technology to remove microorganisms and associated endotoxin from biocide-free MWFs without disrupting chemical integrity. The research will examine the interactions between MWF chemistry, membrane transport, and ingredient retention. Second, the research will examine a novel application of flow cytometry technology for real-time microbial detection in MWFs. The research will evaluate the physicochemical conditions that maximize flow cytometry performance in MWF applications. Third, an optimal control system will be developed based on flow cytometry and microfiltration. The control system will utilize artificial intelligence methodologies on-line to dynamically predict the required microbial removal rate and optimal microfiltration operating parameters.The control system aims to eliminate microbial-based health risks to approximately 1.2 million workers in the United States. The system would also significantly improve the competitive position of the United States machine tool industry by reducing environmental impact, lowering total machining costs, and minimizing MWF performance variability by enabling contaminant removal and recycling. These considerations are of increasing importance since legislative pressure is mounting at the national level to compel the industry to address the environmental and health risks associated with MWF applications (e.g., EPA Metal Products and Machinery Rule and NIOSH Recommended MWF Exposure Criteria). Recent studies have also demonstrated that total MWF system costs, including acquisition, disposal, and maintenance, are significant in machining, in many cases far-outweighing the cost of tooling. Owing to the technical difficulty removing MWF from manufacturing processes, these drivers will continue to push industry demand for biocide-free microbial control systems and recycling of MWFs to reduce health risks, cost, environmental impact, and performance variability.