CN119468009A

CN119468009A - An automatic lubrication control system

Info

Publication number: CN119468009A
Application number: CN202411638106.4A
Authority: CN
Inventors: 宋成
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-11-16
Filing date: 2024-11-16
Publication date: 2025-02-18

Abstract

The present invention discloses an automatic lubrication control system, which belongs to the technical field of lubrication systems. The system monitors the lubrication systems of equipment on industrial sites in real time to reduce the failure rate. The system comprises a plurality of two-line distributors, a control layer and a platform layer. The plurality of two-line distributors are arranged in one-to-one correspondence with a plurality of lubrication pumps in the lubrication systems of the industrial equipment. Each two-line distributor is used to distribute the lubricant from its corresponding lubrication pump to its corresponding lubrication point and collect its own operating status data. The control layer comprises a programmable control module and an Internet of Things gateway device. The programmable controller module is used to analyze and process the operating status data, and generate a control instruction when it is analyzed that the operating status data meets the preset early warning standard. The control layer controls the corresponding two-line distributor and/or the lubrication system to perform corresponding actions according to the control instruction. The Internet of Things gateway device transmits the real-time status information and data of the lubrication system to the platform layer, and converts them into business data at the platform layer.

Description

Automatic lubrication control system

Technical Field

The invention relates to the technical field of lubrication systems, in particular to an automatic lubrication control system.

Background

In the operation of modern industrial equipment, the efficiency and reliability of the lubrication system has a significant impact on the overall performance of the equipment. Lubrication not only reduces friction between mechanical parts, but also extends the service life of the device. However, conventional lubrication systems rely primarily on manual inspection, which has a number of limitations:

Firstly, manual inspection generally cannot realize real-time monitoring, and equipment cannot be found in time when lubrication faults occur easily, so that serious consequences such as equipment abrasion and even shutdown are caused. Equipment downtime may cause production interruptions, affecting product delivery and production schedule. Secondly, the frequency and accuracy of manual detection are limited by human resources and technical level, and it is difficult to ensure that the lubrication system is always in an optimal state. In addition, the possible omission in the manual inspection process also increases the maintenance cost and downtime of the enterprise.

The foregoing background is only for the purpose of facilitating an understanding of the principles and concepts of the application and is not necessarily in the prior art to the present application and is not intended to be used as an admission that such background is not entitled to antedate such novelty and creativity by virtue of prior application or that it is already disclosed at the date of filing of this application.

Disclosure of Invention

The application provides an automatic lubrication control system which can monitor a lubrication system of equipment in an industrial field in real time and reduce the failure rate.

In order to achieve the purpose, the embodiment of the application discloses an automatic lubrication control system which comprises a plurality of double-wire distributors and a control layer, wherein the double-wire distributors are arranged in one-to-one correspondence with a plurality of lubrication pumps in a lubrication system of industrial equipment, each double-wire distributor is used for distributing lubricant from the corresponding lubrication pump to the corresponding lubrication point and collecting operation state data of the double-wire distributor, the control layer comprises a programmable controller module, the programmable controller module is used for analyzing and processing the operation state data, when the operation state data is analyzed to meet the preset early warning standard, a control instruction is generated, and the control layer controls the corresponding double-wire distributors and/or the lubrication system to execute corresponding actions according to the control instruction.

In the embodiment of the application, the lubricant is distributed to the corresponding lubrication points through the one-to-one correspondence of the two-wire distributor and the lubrication pump of the industrial equipment, and the running state data of the lubricant is collected in real time and transmitted to the control layer. In this way, the data can be analyzed and processed by the programmable controller module of the control layer. When the running state data is in a preset early warning value range (greater than a set value and/or less than the set value), the programmable controller module generates control instructions, and the control layer performs corresponding operations (such as adjusting lubricant distribution, closing fault lubrication points and the like) according to the instructions. Therefore, the real-time monitoring of the lubrication system is realized, so that the abnormal condition can be found in time, measures can be taken in time to solve the abnormal condition, and the failure rate can be effectively reduced. In addition, the frequency of manual inspection and possible omission are reduced, and the maintenance cost of enterprises can be effectively reduced. In conclusion, the effects of reducing the cost can be achieved.

In some possible embodiments, the two-wire dispenser is a wireless transmission two-wire type, the operation state data comprise filling pressure data at each oil outlet of the two-wire dispenser, the two-wire dispenser comprises pressure sensors arranged at each oil outlet, the two-wire dispenser collects the filling pressure data through the pressure sensors, the programmable controller module comprises a central processing unit, the central processing unit is used for analyzing the filling pressure data, a control instruction is generated when the filling pressure data are analyzed to be within a preset early warning value range, and the control layer controls the corresponding two-wire dispenser to execute corresponding actions according to the control instruction. The two-wire distributor transmits the running state data in a wireless mode, so that the wiring requirement of the system can be simplified, the complexity of installation and maintenance is reduced, and the flexibility of system deployment is improved. The central processing unit monitors the filling pressure data in real time, so that the response speed and the maintenance efficiency of the system can be improved. Specifically, when the abnormal pressure drop of a certain lubrication point or the pressure smaller than a set value is monitored, the system can immediately adjust the supply quantity of the lubricant or give out fault early warning to prevent equipment from being worn or failed due to improper lubrication.

In some possible embodiments, the automatic lubrication control system further comprises a platform layer, the platform layer is used for receiving the running state data sent by the control layer, the platform layer further comprises a data analysis module, and the data analysis module is used for drawing a lubrication system working state diagram, a temperature, humidity and flow data curve and a filling pressure trend diagram according to the filling pressure data. Therefore, maintenance personnel can intuitively observe the pressure change condition through a lubrication system working state diagram, a temperature, humidity and flow data curve and a filling pressure trend diagram to judge the system state, thereby being beneficial to predicting possible faults in advance and taking preventive measures.

In some possible embodiments, the control layer includes an internet of things gateway device and a programmable controller, the control layer exchanges data with the platform layer through the internet of things gateway device, and the programmable controller executes a control instruction sent by the platform layer. Thus, the data processing speed and efficiency are improved, and the delay is reduced.

In some possible implementations, the programmable controller is configured with a touch screen. In this way, the running state of the system is checked in real time through the touch screen, and in addition, an intuitive user interface can be provided, so that the operation and monitoring are convenient.

In some possible implementations, the platform layer is a public cloud or a private cloud server. In this way, on one hand, flexible computing resources can be provided to adapt to different service demands, and on the other hand, the security and reliability of data storage can be realized.

In some possible embodiments, the operating state data further comprises lubricant addition data of each lubrication point of the two-wire distributor, the two-wire distributor further comprises a plurality of volume sensors, the plurality of volume sensors are arranged corresponding to the plurality of lubrication points of the two-wire distributor, and each volume sensor is used for collecting the lubricant addition data of the corresponding lubrication point;

The programmable controller module comprises a sensor unit, the sensor unit is used for analyzing the lubricant adding amount data of each lubrication point, when the lubricant adding amount data of each lubrication point is analyzed to be larger than a corresponding preset early warning value, a control command is generated, and the control layer controls the double-wire distributor to stop supplying lubricant to the corresponding lubrication point according to the control command. In this way, the lubricant can be ensured to be supplied as required, and excessive supply is avoided, so that on one hand, the waste of the lubricant is avoided, and the cost is reduced, and on the other hand, the temperature rise of the bearing caused by excessive lubricant can be avoided. In addition, by adopting a positive displacement metering mode, the oil feeding quantity can be accurate and is not influenced by the system pressure.

In some possible embodiments, the operational status data further includes motion data of an internal piston of the two-wire dispenser, the two-wire dispenser further including a hall sensor and a channel sensor, the two-wire dispenser collecting motion data of the internal piston of the two-wire dispenser via the hall sensor and the channel sensor. Thus, the action of the internal piston can be monitored in real time, the normal operation of the double-wire distributor is ensured, and the lubricant is stably supplied.

In some possible embodiments, the automatic lubrication control system further includes an application layer, and the platform layer is in data exchange connection with the application layer, and is configured to send setting data to the application layer or receive a control instruction sent by the application layer, and send the setting data to the control layer, so as to remotely control the two-wire distributor and/or the lubrication system to perform a corresponding action. On the one hand, the system can realize remote monitoring and control, is convenient to manage, and on the other hand, is convenient to inform maintenance personnel to immediately take measures to prevent equipment from being damaged or stopped.

In some possible embodiments, the application layer at least comprises one of a WeChat applet based on cloud data, installed application software and a webpage client in a preset terminal device. Thus, the user can check and control the lubrication system conveniently, and the convenience in use can be improved.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it being understood that like reference numerals denote like elements throughout the drawings. In the drawings, the dimensions of some of the features may be modified for clarity of understanding.

FIG. 1 is a schematic diagram of an automatic lubrication control system according to some embodiments of the present application;

FIG. 2 is a schematic illustration of the configuration of a two-wire dispenser in the automatic lubrication control system of FIG. 1;

FIG. 3 is a schematic view of the control layer structure of the automatic lubrication control system shown in FIG. 1;

FIG. 4 is a schematic diagram of a programmable controller module in the control layer shown in FIG. 3;

FIG. 5 is a schematic view of a platform layer structure in the automatic lubrication control system of FIG. 1;

FIG. 6 is a schematic diagram of a user interface of an application layer in the automatic lubrication control system of FIG. 1.

Detailed Description

The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

It should be noted that, in the description of the present invention, terms such as "medium," "upper," "lower," "transverse," "inner," and the like indicate directions or positional relationships based on the directions or positional relationships shown in the drawings, which are merely for convenience of description, and do not indicate or imply that the apparatus or elements must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.

In addition, it should be noted that, in the description of the present invention, unless explicitly specified and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, integrally connected, mechanically connected, directly connected, indirectly connected through an intermediate medium, or communicating between the two elements. The specific meaning of the above terms in the present invention can be understood by those skilled in the art according to the specific circumstances.

Referring to fig. 1 and 2, an embodiment of the present application provides an automatic lubrication control system, which includes a plurality of two-wire distributors 1 and a control layer 2, where the plurality of two-wire distributors 1 are disposed in one-to-one correspondence with a plurality of lubrication pumps in a lubrication system of an industrial device, and each two-wire distributor 1 is configured to distribute a lubricant from its corresponding lubrication pump to its corresponding lubrication point and collect its own operation state data, and the lubricant may be a lubricating oil or a lubricating grease, for example.

The control layer 2 comprises a programmable controller module 21, the programmable controller module 21 is used for analyzing and processing the running state data, when the running state data are analyzed to meet the preset early warning standard, a control instruction is generated, and the control layer 2 controls the corresponding two-wire distributor 1 and/or the lubricating system to execute corresponding actions according to the control instruction.

In this way, the two-wire distributor 1 is in one-to-one correspondence with the lubrication pumps of the industrial plant, distributes the lubricant to the corresponding lubrication points, and collects the operating state data thereof in real time and transmits it to the control layer 2. In this way, the data can be analyzed and processed by the programmable controller module 21 of the control layer 2. When the operating state data is within a preset early warning value range (greater than a set value and/or less than a set value), the programmable controller module 21 generates control instructions, and the control layer 2 performs corresponding operations (such as adjusting lubricant distribution, closing a fault lubrication point, etc.) according to the instructions. Therefore, the real-time monitoring of the lubrication system is realized, so that the abnormal condition can be found in time, measures can be taken in time to solve the abnormal condition, and the failure rate can be effectively reduced. In addition, the frequency of manual inspection and possible omission are reduced, and the maintenance cost of enterprises can be effectively reduced. In conclusion, the effects of reducing the cost can be achieved.

Referring to fig. 2-4, in some embodiments, the two-wire dispenser 1 is a wireless transmission two-wire dispenser, the operation status data includes filling pressure data at each oil outlet of the two-wire dispenser 1, the two-wire dispenser 1 includes a pressure sensor 11 disposed at each oil outlet, the two-wire dispenser 1 collects the filling pressure data through the pressure sensor 11, the programmable controller module 21 includes a central processing unit 211, the central processing unit 211 is used for analyzing the filling pressure data, and generating a control command when the filling pressure data is analyzed to be within a preset early warning value range, and the control layer 2 controls the corresponding two-wire dispenser 1 to execute a corresponding action according to the control command. The two-wire distributor 1 transmits the running state data in a wireless mode, so that the wiring requirement of the system can be simplified, the complexity of installation and maintenance is reduced, and the flexibility of system deployment is improved. By monitoring the filling pressure data in real time by the central processing unit 211, the response speed and maintenance efficiency of the system can be improved. Specifically, when the abnormal pressure drop of a certain lubrication point or the pressure smaller than a set value is monitored, the system can immediately adjust the supply quantity of the lubricant or give out fault early warning to prevent equipment from being worn or failed due to improper lubrication.

Referring to fig. 5, in some embodiments, the automatic lubrication control system further includes a platform layer 3, the platform layer 3 is configured to receive the running state data sent by the control layer 2, the platform layer 3 further includes a data analysis module 31, and the data analysis module 31 is configured to draw a lubrication system working state diagram, a temperature, humidity, flow data curve, and a filling pressure trend diagram according to the filling pressure data. Therefore, maintenance personnel can intuitively observe the pressure change condition through a lubrication system working state diagram, a temperature, humidity and flow data curve and a filling pressure trend diagram to judge the system state, thereby being beneficial to predicting possible faults in advance and taking preventive measures.

In some embodiments, the platform layer 3 is a public cloud or private cloud server. In this way, on one hand, flexible computing resources can be provided to adapt to different service demands, and on the other hand, the security and reliability of data storage can be realized.

Referring to fig. 3, in some embodiments, the control layer 2 includes an internet of things gateway device 23 and a programmable controller 22, the control layer 2 exchanges data with the platform layer 3 through the internet of things gateway device 23, and executes a control instruction sent by the platform layer 3 through the programmable controller 22. Thus, the data processing speed and efficiency are improved, and the delay is reduced.

In some embodiments, programmable controller 22 is configured with a touch screen. In this way, the running state of the system is checked in real time through the touch screen, and in addition, an intuitive user interface can be provided, so that the operation and monitoring are convenient. Specifically, the touch screen can be used for displaying all records of current alarms and historical faults, carrying out remote communication, uploading the data of the control layer 2 to the platform layer 3, and receiving cloud data and control instructions of the platform layer 3.

Referring to fig. 2 and 4, in some embodiments, the operating status data further includes lubricant addition data for each lubrication point of the two-wire dispenser 1, the two-wire dispenser 1 further includes a plurality of volume sensors 12, the plurality of volume sensors 12 being disposed corresponding to a plurality of lubrication points of the two-wire dispenser itself, each volume sensor 12 being configured to collect lubricant addition data for its corresponding lubrication point;

The programmable controller module 21 includes a sensor unit 212, where the sensor unit 212 is configured to analyze the lubricant adding amount data of each lubrication point, and generate a control command when the lubricant adding amount data of each lubrication point is greater than a corresponding preset early warning value, and the control layer 2 controls the two-wire distributor 1 to stop supplying lubricant to the corresponding lubrication point according to the control command. In this way, the lubricant can be ensured to be supplied as required, and excessive supply is avoided, so that on one hand, the waste of the lubricant is avoided, and the cost is reduced, and on the other hand, the temperature rise of the bearing caused by excessive lubricant can be avoided. In addition, by adopting a positive displacement metering mode, the oil feeding quantity can be accurate and is not influenced by the system pressure.

In some embodiments, the operational status data further includes motion data of the internal piston of the two-wire dispenser 1, the two-wire dispenser 1 further including a hall sensor 13 and a channel sensor 14, the two-wire dispenser 1 collecting motion data of the internal piston of the two-wire dispenser 1 via the hall sensor 13 and the channel sensor 14. Thus, the internal piston action can be monitored in real time, and the normal operation of the two-wire distributor 1 and the stable supply of the lubricant can be ensured.

It will be appreciated that the above embodiments are only schematically presented for some of the components of the two-wire splitter 1 and are not to be construed as merely comprising these components of the two-wire splitter 1. For example, the two-wire dispenser 1 further includes a controller, a wireless communication module, and a battery.

Referring to fig. 1 and 6, in some embodiments, the automatic lubrication control system further includes an application layer 4, where the platform layer 3 is in data exchange connection with the application layer 4, and is configured to send setting data to the application layer 4 or receive a control instruction sent by the application layer 4, and send the setting data to the control layer 2, so as to remotely control the two-wire distributor 1 and/or the lubrication system to perform a corresponding action. On the one hand, the system can realize remote monitoring and control, is convenient to manage, and on the other hand, is convenient to inform maintenance personnel to immediately take measures to prevent equipment from being damaged or stopped.

By way of example, system information may be transmitted to a cloud, server, or smart phone client via a 4G/5G SIM card that has activated data transmission, with up to 256 contacts (including but not limited to maintenance personnel) being configurable for short message service.

Of course, the present application is not limited thereto. In other embodiments, the application layer 4 may be further configured to freely configure device indicators, configure after-sales flows, freely define B I and reports, support secondary development through interfaces through an open API library, support data access for other systems, support custom development and deep algorithm analysis based on data and artificial intelligence, and 4) support overseas device access and multilingual and world map applications.

In some embodiments, the application layer 4 at least comprises one of a WeChat applet based on cloud data, installed application software and a webpage client in a preset terminal device. Thus, the user can check and control the lubrication system conveniently, and the convenience in use can be improved.

Of course, the present application is not limited thereto. In other embodiments, the operating status data may also include information such as temperature, angle, signal value, communication status, signal strength, battery level, temperature and humidity of the two-wire dispenser 1 itself.

The oil level of the oil storage cylinder can be monitored through the cooperation of the control layer 2 and the platform layer 3, oil supplementing of the oil supplementing pump can be automatically controlled according to the oil level, such as an over-low stop alarm and an over-high overflow alarm prompt of the oil level, the operation state of the lubricating pump is monitored, various protections such as overload, short circuit and over-current are provided, the oil supply state of the lubricating pump is monitored, the alarm is automatically provided if the oil supply exceeds a set time, the pressure of the lubricating pump is monitored, the automatic stop alarm is provided when the set pressure of the lubricating pump exceeds the set pressure of the lubricating pump, the action state of the reversing valve and the inlet and outlet pressure are automatically detected, such as the valve failure can be automatically stopped, the oil filling amount and the oil filling period are determined according to the characteristics and the rotating speed requirement of the equipment bearing, the oil is automatically timed and quantitatively filled, the failure alarm is output to abnormal point positions through the self-detection of temperature, humidity, acceleration, electric quantity and flow signals of the lubricating system, and the failure is timely locked and eliminated.

The control layer 2 may also implement manual control. The platform layer 3 can realize detailed records of oil supply data of all oil supply points according to the reported data of the two-wire distributor 1, and can classify and record fault information of the distributor. In addition, remote debugging and downloading SGLAN of devices in the network, such as the programmable controller 22, a touch screen with communication function, etc. can be supported.

It will be appreciated that the automatic lubrication control system is applicable to most industrial environments, for example, that applicable in iron and steel enterprises include:

1) The temperature is high, the point positions are multiple, and continuous production areas such as steelmaking crown blocks, continuous casting areas and the like are realized.

2) The automatic degree is high, and the rotating speed is high, such as hot rolling pressure measuring machine, plate coil box, laminar flow roller way, conveying roller way, working roller, cold rolling furnace roller, twenty rollers, six frames, finishing machine set, etc. 3) The area is large, the point positions are more, and the area needing manual inspection, such as an ironmaking belt, is needed.

With the support of the automatic lubrication control system, the benefits in the field include:

1) The intelligent control can realize automatic inspection, state monitoring, trend analysis, fault alarm and the like, reduce the on-site workload of workers, reduce unnecessary shutdown, reduce equipment for personnel to approach to operation and eliminate potential safety hazards.

2) The oil filling amount is accurately controlled, the consumption of grease is reduced, the environmental protection and fire fighting hidden trouble caused by the accumulation of redundant grease are reduced, and meanwhile, the aim of saving the cost is achieved.

The invention and its embodiments have been described above with no limitation, and the actual construction is not limited to the embodiments of the invention as shown throughout. In summary, if one of ordinary skill in the art is informed by this disclosure, a structural manner and an embodiment similar to the technical solution should not be creatively devised without departing from the gist of the present invention.

Claims

1. An automatic lubrication control system, characterized by comprising:

A plurality of two-line distributors, each of which is arranged in one-to-one correspondence with a plurality of lubrication pumps in a lubrication system of an industrial device, and each of which is used to distribute lubricant from its corresponding lubrication pump to its corresponding lubrication point and collect its own operating status data;

The control layer includes a programmable controller module, and the programmable controller module is used to analyze and process the operating status data. When it is analyzed that the operating status data meets the preset early warning standard, a control instruction is generated; the control layer controls the corresponding two-line distributor and/or lubrication system to perform corresponding actions according to the control instruction.

2. The automatic lubrication control system according to claim 1, characterized in that the two-line distributor is a wireless transmission two-line type, the operating status data includes filling pressure data at each oil outlet of the two-line distributor, the two-line distributor includes a pressure sensor arranged at each oil outlet, and the two-line distributor collects the filling pressure data through the pressure sensor;

The programmable controller module includes a central processing unit, which is used to analyze the filling pressure data and generate a control instruction when it is analyzed that the filling pressure data is within a preset warning value range; the control layer controls the corresponding two-line distributor to perform corresponding actions according to the control instruction.

3. The automatic lubrication control system according to claim 2 is characterized in that it also includes a platform layer, which is used to receive the operating status data sent by the control layer. The platform layer also includes a data analysis module, which is used to draw a lubrication system working status diagram, temperature, humidity and flow data curves and a filling pressure trend diagram based on the filling pressure data.

4. The automatic lubrication control system according to claim 3 is characterized in that the control layer includes an Internet of Things gateway device and a programmable controller, the control layer exchanges data with the platform layer through the Internet of Things gateway device, and executes the control instructions sent by the platform layer through the programmable controller.

5. The automatic lubrication control system according to claim 4, characterized in that the programmable controller is equipped with a touch screen.

6. The automatic lubrication control system according to claim 3, characterized in that the platform layer is a public cloud or a private cloud server.

7. The automatic lubrication control system according to any one of claims 2 to 6, characterized in that the operating status data also includes lubricant addition amount data of each lubrication point of the dual-line distributor; the dual-line distributor also includes a plurality of volume sensors, the plurality of volume sensors are arranged corresponding to the plurality of lubrication points thereof, and each of the volume sensors is used to collect the lubricant addition amount data of the corresponding lubrication point;

The programmable controller module includes a sensor unit, which is used to analyze the lubricant addition data of each lubrication point. When it is analyzed that the lubricant addition data of each lubrication point is greater than its corresponding preset warning value, a control instruction is generated. The control layer controls the two-line distributor to stop supplying lubricant to the corresponding lubrication point according to the control instruction.

8. An automatic lubrication control system according to any one of claims 2-6, characterized in that the operating status data also includes the action data of the internal piston of the two-line distributor, and the two-line distributor also includes a Hall sensor and a channel sensor, and the two-line distributor collects the action data of the internal piston of the two-line distributor through the Hall sensor and the channel sensor.

9. The automatic lubrication control system according to claim 3 is characterized in that it also includes an application layer, and the platform layer is connected to the application layer for data exchange, and is used to send setting data to the application layer or receive control instructions sent by the application layer, and send them to the control layer, so as to remotely control the two-line distributor and/or lubrication system to perform corresponding actions.

10. The automatic lubrication control system according to claim 9, characterized in that the application layer includes at least one of the following options: a WeChat applet based on cloud data in a preset terminal device, installed application software, and a web client.