Annealing kiln roller way bearing full-automatic lubricating system and method based on array combination control

Abstract

The invention discloses an annealing furnace roller way bearing full-automatic lubricating system and method based on array combination control, and relates to the field of automatic lubrication of industrial equipment. The system comprises a pneumatic lubricating machine, a PLC, an HMI, a pressure transmitter and a matrix relay set, m * n lubricating points are controlled through m + n + 1 DO points, and control resources are greatly saved. Parameters such as lubricating period and oil injection time are set through the HMI, the PLC selects a target lubricating point according to matrix combination, the pneumatic lubricating machine is driven to quantitatively inject grease, and the pressure transmitter monitors pressure in real time. The system can automatically recognize faults such as blockage and leakage and give an alarm, and timing, quantitative and full-automatic lubrication is achieved. The system has high precision, high reliability and strong expansibility, solves the defects of manual lubrication and the problems of high complexity and high cost of a traditional centralized lubrication system, effectively prolongs the service life of equipment, and reduces the maintenance cost.

Description

Technical Field

[0001] This invention relates to the field of automatic lubrication technology for industrial equipment, specifically a fully automatic lubrication system and method for annealing kiln roller bearings based on array combination control. Background Technology

[0002] Annealing furnaces are critical equipment in glass production. Their roller conveyors are supported by hundreds of bearings, requiring regular, quantitative, and reliable grease application to ensure long-term stable operation and reduce wear and energy consumption. Traditional lubrication methods rely primarily on manual, periodic lubrication. Manual lubrication suffers from high labor intensity, inaccurate lubrication cycles and dosages, easy omissions, and grease contamination. Existing centralized lubrication systems, if equipped with independent control valves for each lubrication point, result in an extremely large number of digital output (DO) points in the control system, complex electrical wiring, a bulky control cabinet, high costs, and difficulties in troubleshooting. Furthermore, existing systems often lack real-time monitoring and feedback on the effectiveness of each lubrication action, failing to guarantee "quality" lubrication. Blockages or leaks in any lubrication path are difficult to detect immediately, potentially leading to bearing damage.

[0003] Therefore, there is an urgent need to develop a lubrication system that can achieve precise, reliable, and automatic lubrication of a large number of lubrication points, while significantly reducing the complexity and cost of the control system. Summary of the Invention

[0004] This invention aims to overcome the shortcomings of existing technologies and provides a fully automatic lubrication system and method for annealing kiln roller bearings. The system includes the following functions:

[0005] Pneumatic lubrication machine: As a power source, it outputs lubricating grease under the drive of compressed air.

[0006] The air passage of the pneumatic lubricator is controlled by an air passage control solenoid valve, which is also controlled by a DO point of a programmable controller.

[0007] Control system: includes programmable logic controller (PLC), human-machine interface (HMI), and pressure signal detection element.

[0008] The programmable controller's digital output (DO) module requires only (m+n) output points to independently control m row relays and n column relays.

[0009] Pressure transmitter: Installed at the end of the main distribution oil circuit of the pneumatic lubrication machine, it is used to detect the working pressure of the lubrication system in real time and feed the pressure signal back to the analog input (AI) module of the programmable controller.

[0010] Control logic: Stored in the programmable logic controller (PLC). The lubrication cycle and the amount of oil injected at each lubrication point (controlled by injection time) parameters can be set on the HMI. During operation, the PLC uniquely selects a target lubrication point by activating a specific combination of a row relay and a column relay in a preset sequence. Then, the PLC activates the pneumatic control solenoid valve, driving the pneumatic lubrication machine to inject oil into the selected lubrication point within the set injection time. Simultaneously, the PLC monitors the pressure transmitter signal; if the pressure value does not reach the normal range during injection, it determines that there may be a blockage or leak at that point and records an alarm. After lubrication of one point is completed, the system sequentially switches to the next lubrication point until all points are lubricated, then enters a waiting cycle.

[0011] Based on the above system, the present invention also provides a fully automatic lubrication method, comprising the following steps: S1. Parameter settings: Set the total number of lubrication points (M=m×n), lubrication cycle T, standard oil injection time t for each lubrication point, and normal operating pressure range of the lubrication system [P_min,P_max] via HMI.

[0012] S2. Select the lubrication point. The PLC generates the coordinates (i,j) of the target point that needs lubrication according to the internal program or preset sequence, and outputs control signals to turn on the i-th row relay and the j-th column relay.

[0013] S3. Start lubrication. The PLC controls the solenoid valve of the air circuit to open, and the compressed air drives the pneumatic lubrication machine to start supplying grease to the selected lubrication point (i,j).

[0014] S4. Timing and Monitoring: When lubrication is started, the PLC starts timing and reads the pressure transmitter value P in real time.

[0015] S5. Judgment and Stop: When the timer reaches the set oil injection time t, the PLC closes the air circuit control solenoid valve to stop the oil supply, and then closes the i-th row solenoid valve and the j-th column solenoid valve.

[0016] S6. Validity Judgment: During the timing period of step S4, if the pressure value P remains below P_min, it is determined that the lubrication point pipeline is blocked or the lubrication machine is malfunctioning; if the pressure value P cannot be established (remains extremely low) or is abnormally low, it may indicate a serious leak. The PLC records the coordinates of the abnormal point and the fault type, and triggers an HMI alarm.

[0017] S7. Cycle and Waiting: After the system completes lubrication according to the number of lubrication points, lubrication cycle, and oil injection amount (time), it enters a waiting state until the next lubrication cycle T arrives, and then the cycle starts again from the beginning.

[0018] Compared with the prior art, the beneficial effects of the present invention include: 1. Significantly saves control resources. Through the m×n matrix solenoid valve group design, only (m+n+1) DO points are needed to control M (=m×n) lubrication points. For example, 12+20+1=33 DO points can control 240 lubrication points, reducing the number of DO points by about 86%, which greatly reduces the cost of PLC hardware, control cabinet size and wiring complexity.

[0019] 2. Fully automatic and high-precision, it achieves timed and quantitative fully automatic lubrication, avoiding the uncertainty of manual lubrication, ensuring the consistency of lubrication for each bearing, and extending the service life of the equipment.

[0020] 3. It has status monitoring and alarm functions. Through the pressure transmitter, it can monitor the system pressure in real time, effectively identify faults such as lubrication point blockage and leakage, achieve "quality" lubrication, improve the reliability and maintainability of the system, and avoid equipment damage caused by lubrication failure.

[0021] 4. High flexibility and scalability: Lubrication cycles and oil injection volumes can be easily adjusted by modifying the PLC program and HMI parameters. When expanding the system scale (number of lubrication points), only corresponding solenoid valves and a small number of DO points need to be added, resulting in low expansion costs. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Figure 1 This is the overall flowchart of the method of the present invention.

[0024] Figure 2 This is a system schematic diagram of the present invention.

[0025] Figure 3 This is a schematic diagram of the matrix control principle of the present invention.

[0026] Figure 4 This is the electrical control schematic diagram of the CPU of this invention.

[0027] Figure 5 This is the electrical control schematic diagram of the DO of this invention.

[0028] Figure 6 This is a schematic diagram of the electrical control principle of the solenoid valve of this invention.

[0029] Figure 7 This is the electrical control schematic diagram of the AI ​​module of this invention.

[0030] Figure 8 This is a schematic diagram of the terminal wiring of the present invention. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] Example 1 A method for fully automated lubrication of roller bearings in an annealing kiln based on array combination control includes the following steps: S1. Parameter settings. Set the total number of lubrication points (M=m×n), lubrication cycle T, standard lubrication time t1 for each lubrication point, lubrication interval t2 between two lubrication points, and normal operating pressure range of the lubrication system [P_min,P_max] through the HMI.

[0033] Total number of lubrication points M: Determined based on the number of roller bearings, with a total of 12×10×2 lubrication points; Lubrication cycle T: Based on bearing speed, load and grease life, T is set to 1 month, meaning full-point lubrication is completed once a month; Standard lubrication time t1: Calibrated according to bearing model and grease requirement, t1 is set to 1 second, corresponding to a grease injection amount of approximately 0.5g / point. Actual testing verifies that lubrication is sufficient and without waste. Lubrication interval t2: The duration of lubrication between two lubrication points, default t2=5 seconds; Normal operating pressure range [P_min, P_max]: Based on the oil circuit length, pipe diameter and grease viscosity, P_min is set to 0.4MPa and P_max to 0.5MPa, matched to the measurement range of the Rosemount 3051TG transmitter; Additional parameters: The alarm delay time is set to 3 seconds to avoid false alarms due to instantaneous pressure fluctuations; the number of fault retry attempts is set to 1. If the fault point is still abnormal after automatically retrying once, an alarm will be recorded.

[0034] S2. System Startup. Press the start button to begin the first lubrication operation. The CPU controls the opening of the pneumatic lubrication machine's air source YV_0, driving the Lincoln P205 pneumatic lubrication machine to continuously inject oil into the pipeline. The AI ​​module collects the 4-20mA signal from the Rosemount 3051TG pressure transmitter in real time and converts it into the actual pressure value P. The CPU compares the actual pressure value P with the set working pressure range [P_min, P_max], opening or closing YV_0 accordingly to maintain the pressure within a stable working range and ensure the system's operating pressure. The CPU's electrical control schematic is shown below. Figure 4 As shown.

[0035] After the internal pressure of the pipeline stabilizes, lubrication is performed on each roller conveyor according to the set number of lubrication points M and the interval t2 between two lubrication points. The operation is as follows: (1) Figure 5 Q0.0 and Q3.0 are output simultaneously and held for 1 second, driving... Figure 6 The relays YV_A and YV_L01 of operate simultaneously for 1 second, lubricating the lubrication point A L01. During lubrication, AI continuously tracks the pipeline pressure. If the pressure does not decrease, a lubrication alarm is output; if the pressure decreases normally, the lubrication is successful; (2) Whether the lubrication of the lubrication point A L01 is successful or not, after an interval of 5 seconds, the CPU drives Figure 5 Q0.0 and Q3.1 of output simultaneously for 1 second, causing Figure 6 the relays YV_A and YV_L02 of to operate simultaneously for 1 second, lubricating the lubrication point A L02. And so on, until the lubrication point J 12 is lubricated, and the first lubrication is completed entirely.

[0036] (3) Check the alarm record on the HMI, check the corresponding solenoid valve, circuit, and pipeline of this lubrication point, and after troubleshooting, manually jog to lubricate it; After an interval time T = 1 month, the system conducts the second overall lubrication.

[0037] Embodiment 2 Based on the above method, the present invention provides a full-automatic lubrication system for the annealing furnace roller table bearings based on array combination control, and the specific functions include: The system includes basic hardware such as PLC, HMI, relays, gas sources, gas circuit control solenoid valves, pneumatic lubricators, pressure buffers, pressure transmitters, and lubricating oil pipelines; All control parameters are set through the touch screen, including lubrication cycle, number of lubrication points, lubricating oil consumption, etc.; In the automatic state of the system, the PLC controls the relay matrix, and the horizontal and vertical coordinates provide positive and negative power supplies for the solenoid valves respectively, achieving precise control of the independent opening / closing of the solenoid valves and their opening duration.

[0038] The pneumatic lubricator transports lubricating oil for the system, and through the buffer tank, oil delivery pipe, oil return pipe, pressure transmitter, and PLC, constant pressure control of the lubricating oil pressure is achieved, making the opening duration of the solenoid valve and the oil supply form a stable proportional relationship, achieving the purpose of quantitative lubrication; During the lubrication interval period set on the touch screen, the system lubricates the bearings regularly; the lubrication cycle and lubrication amount can be set proportionally, enabling the bearings to be lubricated "little by little and often", avoiding the influence on lubrication quality after the oil circuit is blocked due to long-term non-operation; At the ends of the two main oil circuits, oil quality inspection solenoid valves are installed, and equipment maintenance personnel regularly check and clean them to ensure the quality of the oil; The system has the function of fault reporting and recording. When it is detected that there is no change in the oil pressure when a certain point is opened for lubrication, it is judged as abnormal, an alarm record is generated, and the lubrication of the next point continues.

Claims

1. A fully automatic lubrication system and method for annealing kiln roller bearings based on array combination control, characterized in that, The system includes a pneumatic lubrication machine, a control system, a pressure buffer, a pressure transmitter, and a matrix relay group. The pneumatic lubrication machine is controlled by a pneumatic control solenoid valve to control the air passage opening and closing. This solenoid valve is connected to a digital output DO point of a programmable logic controller (PLC). The control system includes a PLC, a human-machine interface (HMI), and pressure signal detection elements. The PLC's DO module has m+n output points, which independently control m row relays and n column relays. The target lubrication point is uniquely selected through the combination of row and column relays. The pressure transmitter is installed at the end of the main distribution oil circuit and feeds back the real-time pressure signal to the analog input (AI) module of the PLC.

2. The fully automatic lubrication system for annealing kiln roller bearings based on array combination control according to claim 1, characterized in that, The human-machine interface can be configured with the total number of lubrication points M, lubrication cycle T, lubrication time t for a single lubrication point, and normal operating pressure range of the system [P_min, P_max]. The parameters are stored in the PLC and used as the basis for control logic.

3. The fully automatic lubrication system for annealing kiln roller bearings based on array combination control according to claim 1, characterized in that, The pressure damper is installed between the output end of the pneumatic lubricator and the oil circuit to stabilize the output pressure of the lubricating grease, so that the opening time of the solenoid valve and the oil supply are in a stable and proportional relationship.

4. The fully automatic lubrication system for annealing kiln roller bearings based on array combination control according to claim 1, characterized in that, The pneumatic lubrication machine is equipped with an oil quality inspection solenoid valve at the end of the main oil circuit, which allows maintenance personnel to regularly check and clean the grease to ensure its quality.

5. The fully automatic lubrication system for annealing kiln roller bearings based on array combination control according to claim 1, characterized in that, The PLC uses control logic to generate the coordinates of the target lubrication points in a preset order. It supports configurable sequences such as "from left to right" and "from beginning to end". By precisely activating the corresponding row and column relays through control signals, it achieves orderly switching of lubrication points.

6. Based on any one of claims 1-4, a fully automatic lubrication method for annealing kiln roller bearings based on array combination control is provided, characterized in that, Includes the following steps: S1. Parameter settings: Set the total number of lubrication points (M=m×n), lubrication cycle T, standard oil injection time t for each lubrication point, and normal operating pressure range of the lubrication system [P_min,P_max] through the HMI; S2. Select the lubrication point. The PLC generates the coordinates (i,j) of the target point that needs to be lubricated according to the internal program or preset sequence, and outputs control signals to turn on the i-th row relay and the j-th column relay. S3. Start lubrication. The PLC controls the solenoid valve of the air circuit to open, and the compressed air drives the pneumatic lubrication machine to start supplying grease to the selected lubrication point (i,j). S4. Timing and monitoring: When lubrication is started, the PLC starts timing and reads the pressure transmitter value P in real time; S5. Judgment and Stop: When the timer reaches the set oil injection time t, the PLC closes the air circuit control solenoid valve to stop the oil supply, and then closes the i-th row solenoid valve and the j-th column solenoid valve. S6. Validity is determined during the timing period of step S4; S7. Cycle and Waiting: After the system completes lubrication according to the number of lubrication points, lubrication cycle, and oil injection amount (time), it enters a waiting state until the next lubrication cycle T arrives, and then the cycle starts again from the beginning.

7. The fully automatic lubrication method for annealing kiln roller bearings based on array combination control according to claim 6, characterized in that, In step S6, if the pressure value P is consistently lower than P_min, it is determined that the lubrication point pipeline is blocked or the lubrication machine is malfunctioning. If the pressure value P is consistently extremely low or abnormally low, it may indicate a serious leak. The PLC records the coordinates of the abnormal point and the fault type, and triggers an HMI alarm.

8. The fully automatic lubrication method for annealing kiln roller bearings based on array combination control according to claim 6, characterized in that, In step S1, an alarm delay time and the number of fault retries are also set to avoid false alarms due to instantaneous pressure fluctuations. If the fault point is still abnormal after retries, an alarm is recorded.

9. The fully automatic lubrication method for annealing kiln roller bearings based on array combination control according to claim 6, characterized in that, In step S5, after closing the pneumatic control solenoid valve, a preset time is allowed to pass before the oil circuit residual pressure is released, and then the corresponding row relay and column relay are closed.

10. The fully automatic lubrication method for annealing kiln roller bearings based on array combination control according to claim 6, characterized in that, In step S2, the PLC supports a custom lubrication point priority sequence. The coordinates of lubrication points corresponding to key lubrication areas or high-load bearings can be preset through the HMI. The system completes the lubrication operation according to the priority order, giving priority to ensuring the lubrication effectiveness of key parts. The priority sequence can be adjusted according to the operating conditions of the equipment and stored in the PLC.

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