Motor bearing lubricating oil loss near and far early warning system

Abstract

The application discloses a motor bearing lubricating oil loss near and remote early warning system, which comprises a vibration sensor, an alarm, a first fault positioning display lamp, a second fault positioning display lamp, a first counter and a controller. The vibration sensor is used to detect the vibration signal generated when the motor bearing is running. The output end of the controller is electrically connected with the alarm, the two fault positioning display lamps and the first counter, and the input end of the controller is electrically connected with the output end of the vibration sensor. The controller preliminarily locates the fault by analyzing the time interval from the completion of lubricating oil addition to the response of the second alarm, and then displays the location through the two set fault positioning display lamps. Therefore, the staff can more quickly locate the fault reason when determining the bearing lubricating oil loss reason, the fault checking time is greatly shortened, and the maintenance efficiency is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of motor bearing early warning technology, and in particular to a near- and long-range early warning system for motor bearing lubricant deficiency. Background Technology

[0002] As the most precise parts in mechanical equipment, bearings have tolerances approximately one-tenth that of other mechanical components. Therefore, the healthy and efficient operation of bearings is essential for ensuring stable equipment operation and safe production. Bearings are an indispensable component in motors. To reduce friction during bearing rotation and ensure long-term use, lubricating oil is added to the bearing for lubrication. However, due to various factors such as operating conditions and time, the lubricating oil will become ineffective after a period of use. Prolonged lubrication failure will cause bearing wear, and in severe cases, catastrophic consequences such as bearing seizure and spindle breakage.

[0003] In existing technical solutions, to prevent insufficient lubricating oil from adversely affecting the motor bearings, operators manually add lubricating oil at specified time intervals during actual operation to protect the motor bearings. However, due to various factors such as the duration of motor operation and operating conditions, problems may occur in the motor bearings before the lubricating oil is added. Existing early warning systems can only provide alarms, requiring operators to spend a significant amount of time troubleshooting. Summary of the Invention

[0004] The main objective of this invention is to propose a near- and long-range early warning system for lubricating oil loss in motor bearings. This system aims to provide early warning and alarm when lubricating oil is lacking, and to facilitate easy location and troubleshooting of the cause of the loss, enabling staff to quickly carry out maintenance.

[0005] To achieve the above objectives, the present invention proposes a near-long-range early warning system for insufficient lubricating oil in motor bearings, comprising: a vibration sensor for detecting vibration signals generated when the motor bearing is in operation; monitor; The first counter; and, The controller has its output terminal electrically connected to the alarm, the two fault location indicator lights, and the first counter, and its input terminal electrically connected to the output terminal of the vibration sensor. The controller determines that the motor bearing lubricating oil is insufficient when it receives a high-frequency vibration signal, and controls the display to trigger an alarm. After the motor bearing lubricating oil is replenished, the controller controls the first counter to start counting until the next high-frequency vibration signal is received, and records the time interval x. If x is less than or equal to a set value a, the controller determines it as a first fault and displays it on the display; if x is greater than a and less than or equal to a set value b, the controller determines it as a second fault and displays it on the display.

[0006] Preferably, the device further includes a second counter and a lubricating oil adding device electrically connected to the controller. After the motor bearing is replenished with lubricating oil, the controller controls the second counter to start timing and records the elapsed time as y. If y equals the set value m, it indicates that the lubricating oil in the motor bearing has reached the set usage time and needs to be added, and this is displayed on the display. After the lubricating oil adding device adds lubricating oil to the motor bearing, the controller controls the second counter to reset the measured time y to zero, and displays it on the display and restarts the timing.

[0007] Preferably, the output of the controller is electrically connected to a third counter. After the motor bearing is disassembled, cleaned, and re-lubricated, the controller controls the third counter to measure the total time z of the motor bearing after reinstallation and lubrication. When time z equals the set value n, it indicates that the total time of the motor bearing's lubricating oil has reached the set value and needs to be completely replaced, and this is displayed on the display. After the motor bearing is disassembled, cleaned, and re-lubricated, the controller controls the total time z measured by the third counter to be reset to zero, and this is displayed on the display and the timing is restarted.

[0008] Preferably, the lubricating oil adding device includes an oil storage tank with an oil inlet vertically opened at the top, an oil outlet pipe connected to the bottom end of the oil storage tank, the bottom end of the oil outlet pipe connected to the oil inlet of the motor bearing, and a control valve for controlling its on / off state is provided on it, the control valve being electrically connected to the controller.

[0009] Preferably, the inner cavity of the oil storage tank is provided with a sealing block that can slide vertically, and the top of the sealing block is fixedly connected to a drive mechanism that controls its up and down movement. The sealing block is provided with a one-way valve that is vertically downward and opens in one direction.

[0010] Preferably, the driving mechanism is an electric push rod that is fixedly installed on the top of the oil storage tank and can be vertically extended and retracted. The telescopic end of the electric push rod passes through the oil storage tank and extends into the inner cavity of the oil storage tank and is fixedly connected to the sealing block.

[0011] Preferably, the one-way valve is located directly below the oil inlet.

[0012] Preferably, the bottom of the inner cavity of the oil storage tank is a sloped structure, which is close to the oil outlet pipe and inclined downwards.

[0013] Preferably, the inner wall of the oil storage tank is provided with a sensor for detecting the remaining amount of lubricating oil, and the output end of the sensor is electrically connected to the input end of the controller.

[0014] Preferably, the sensor is a distance measuring sensor for measuring the moving distance of the sealing block, and the distance measuring sensor is located above the sealing block.

[0015] In the technical solution provided by this invention, the display can serve as a warning and label, reminding staff that the motor bearing is lacking lubricating oil. When the controller receives the signal from the vibration sensor, it analyzes the time interval x recorded by the first counter to quickly locate the fault. The fault cause can then be located in real time through the display, allowing staff to make a preliminary judgment and locate the fault cause based on the actual situation. This greatly shortens the time for subsequent fault location and troubleshooting and improves maintenance efficiency. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 A schematic diagram of a principle of an embodiment of the near-long-range early warning system for insufficient lubricating oil in motor bearings provided by the present invention; Figure 2 Provided by the present invention Figure 1 A structural diagram of a lubricating oil adding device; Explanation of icon numbers:

[0018] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0021] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0022] Currently, commonly used near- and far-range early warning systems for low lubricating oil in motor bearings have significant problems. Existing lubricating oil low warning systems can only provide alerts when lubricating oil is low. When faced with a low lubricating oil situation, staff need to spend a lot of time troubleshooting to determine the cause of the lubricating oil loss.

[0023] To address the aforementioned problems, this invention provides a near-long-range early warning system 100 for insufficient lubricating oil in motor bearings. Figures 1 to 2 This is a specific embodiment of the near-long-range early warning system for insufficient lubricating oil in motor bearings provided by the present invention.

[0024] Please see Figure 1The near-long-range early warning system 100 for insufficient lubricating oil in motor bearings includes: a vibration sensor 1, a display 6, a first counter 4, and a controller 2. The vibration sensor 1 is used to detect vibration signals generated when the motor bearing is running. The output terminal of the controller 2 is electrically connected to the alarm, and its input terminal is electrically connected to the output terminal of the vibration sensor 1. The controller 2 is used to determine that the motor bearing is lacking lubricating oil when it receives a high-frequency vibration signal, and to control the alarm to start. After the motor bearing is replenished with lubricating oil, the controller 2 controls the first counter 4 to start counting until the next high-frequency vibration signal is received, and records the time interval x. If x is less than or equal to a set value a, the controller 2 determines it as a first fault and displays it on the display 6; if x is greater than a and less than or equal to a set value b, it determines it as a second fault and displays it on the display 6.

[0025] In the technical solution provided by this invention, the vibration sensor 1 is used to detect the vibration signal generated by the motor bearing during operation in real time, and transmits this signal to the controller 2. When lubricating oil is lacking, the vibration sensor 1 will detect the high-frequency vibration signal generated by the motor bearing due to the lack of lubricating oil, determine that the motor bearing is in a state of lubricating oil deficiency, and control the display 6 to respond with an alarm. After replenishing the motor bearing with lubricating oil, the controller 2 controls the first counter 5 to start recording the time interval x until the next high-frequency vibration signal is received from the vibration sensor 1, and sets two preset values ​​respectively. Let x be a and b, where a is less than b. When x is less than or equal to the set value a, the controller 2 controls the display 6 to show a first fault, indicating that the lubricating oil circuit may be blocked or there may be a problem with the lubricating oil selection. Staff can prioritize these directions for troubleshooting. When x is greater than the set value a and less than or equal to the set value b, the controller 2 controls the display 6 to show a second fault, indicating that the lubricating oil quality has seriously deteriorated after long-term use and needs to be replaced in time. When x is greater than the set value b, it indicates that the lack of lubricating oil is simply due to normal use.

[0026] During the aforementioned fault location process, the display 6 serves as a warning and label, reminding staff that the motor bearing is lacking lubricating oil. When the controller 2 receives the signal from the vibration sensor 1, it analyzes the time interval x recorded by the first counter 4 to quickly locate the fault. The display 6 then displays the fault cause in real time, allowing staff to make a preliminary judgment and locate the fault cause based on the actual situation. This greatly shortens the time required for subsequent fault location and troubleshooting and improves maintenance efficiency.

[0027] When performing vibration testing on the lubricating oil at the motor bearing, the peak vibration acceleration and the vibration acceleration spectrum can well reflect the lubrication condition of the bearing. When the bearing is poorly lubricated, the peak vibration acceleration is high, and a noticeable "weed pile" phenomenon will appear in the part above 2kHz in the vibration acceleration spectrum. As the lubrication deteriorates, the peak vibration acceleration and the amplitude of the "weed pile" will increase significantly. When lubricating oil is insufficient, the bearing will be poorly lubricated. In this case, a noticeable "weed-like" phenomenon will appear in the vibration acceleration spectrum above 2kHz. However, after timely addition of lubricating oil, the "weed-like" phenomenon will quickly improve, restoring lubrication. When oil passage blockage occurs, the added lubricating oil cannot easily reach the motor bearing, making simple lubrication ineffective. The "weed-like" phenomenon will not improve after adding lubricating oil. Therefore, when the interval x is less than the set value a, it indicates that lubricating oil has not reached the motor bearing, indicating an oil passage blockage. When the lubricating oil quality deteriorates, adding lubricating oil will temporarily improve lubrication, causing the peak acceleration to briefly drop to normal levels. However, after a short period, poor lubrication will quickly reappear. Therefore, when the interval x is greater than a but less than the set value b, it indicates poor lubrication due to deteriorated lubricating oil quality.

[0028] To ensure the motor bearings are always lubricated, lubricating oil needs to be added to them at regular intervals. Since the motor's operating time varies, operators can only know the elapsed time since the lubricant was added, but cannot directly assess the actual usage time of the lubricated bearings. To prevent lubricant loss during normal use, in this embodiment of the invention, the near-long-range early warning system 100 for motor bearing lubricant loss further includes a second counter 3 and a lubricant adding device 7 electrically connected to the controller 2. After lubricating oil is added to the motor, the controller 2 controls the second counter 3 to start timing and records the elapsed time as y. If y equals a set value m, it indicates that the lubricating oil in the motor bearing has reached the set usage time and needs to be added, and this is displayed on the monitor. After the lubricant adding device 7 adds lubricating oil to the motor bearing, the controller 2 controls the second counter 3 to reset the measured time y to zero, displaying it on the monitor and restarting the timing. After the motor bearing is replenished with lubricating oil, the second counter 3 records the elapsed time y. When y equals the set value m, it indicates that the lubricating oil in the motor bearing has reached the set usage time. The display 6 shows the information that the lubricating oil has reached the set usage time. At this time, it is necessary to replenish the lubricating oil in the motor bearing. After replenishment, the display 6 shows the information that the lubricating oil replenishment is complete. The second counter 3 resets y to zero and repeats the above operation. This realizes the monitoring of the lubricating oil usage time in the motor bearing, which makes it easy for the staff to intuitively monitor whether the lubricating oil usage time of the motor bearing has reached the specified time and prevent the lubricating oil of the motor bearing from being insufficient under normal use.

[0029] After prolonged use, the lubricating oil in the motor bearing accumulates excessive metal shavings, necessitating a complete replacement to ensure optimal lubrication. Since motor usage time fluctuates, operators can only track the time elapsed between lubricating oil replacements, lacking a clear understanding of the total lubricating oil usage time. In this embodiment, the controller 2's output is electrically connected to a third counter 5. After the motor bearing is disassembled, cleaned, and re-lubricated, the controller 2 controls the third counter 5 to measure the total usage time z after reinstallation and lubrication. When time z equals a set value n, the controller 2 controls the display 6 to show that the total lubricating oil usage time has reached the set duration. Furthermore, after the motor bearing is disassembled, cleaned, and re-lubricated, the controller 2 resets the total time z measured by the third counter 5 to zero and displays it on the display 6, restarting the timer. After the motor bearing is disassembled, cleaned, and lubricated, the controller 2 records the total time z elapsed after the lubricating oil is refilled. When the total time z equals the set value n, it indicates that the total lubricating oil usage time has reached the set time, and the total time indicator light illuminates as a warning, reminding the staff to disassemble, clean, and refill the motor bearing with lubricating oil. After the lubricating oil is refilled, the total time indicator light goes out, indicating that the lubricating oil has been refilled. The third counter 5 then resets z to zero and repeats the above operation, realizing the monitoring of the total lubricating oil usage time at the motor bearing. This allows the staff to intuitively understand whether the total lubricating oil usage time at the motor bearing has reached the specified time, facilitating maintenance.

[0030] When lubricating oil is lacking at the motor bearing, it needs to be added promptly. If lubricating oil is added by a worker, it may not be added in a timely manner. For an embodiment of this invention, please refer to... Figure 2 The lubricating oil adding device 7 includes an oil storage tank 71 with a vertically opening oil inlet at the top. An oil outlet pipe 74 is connected to the bottom of the oil storage tank 71, and the bottom of the oil outlet pipe 74 is connected to the oil inlet of the motor bearing. A control valve 73 is installed on the outlet pipe 74 to control its opening and closing. The control valve 73 is electrically connected to the controller 2. Lubricating oil is added via the lubricating oil adding device 7. After the controller 2 opens the control valve 73, the lubricating oil in the oil storage tank 71 flows through the oil outlet pipe 74 to the oil inlet of the motor bearing. The controller 2 controls the opening and closing of the control valve 73, achieving automated lubricating oil addition to the motor bearing and ensuring timely lubricating oil addition.

[0031] The lubricating oil in the oil storage tank 71 enters through the oil inlet. The flow of the lubricating oil mainly relies on its own gravity, resulting in a slow flow rate and reduced lubricating oil addition efficiency. In this embodiment of the invention, a sealing block 72 is vertically slidable within the inner cavity of the oil storage tank 71. A drive mechanism is fixedly connected to the top of the sealing block 72 to control its up-and-down movement. A one-way valve 75, vertically downward and opening in one direction, is provided on the sealing block 72. When the drive mechanism pushes the corresponding sealing block 72 up and down, the lubricating oil in the inner cavity of the oil storage tank 71 can be discharged more quickly from the oil outlet pipe 74 under the action of its own gravity and the force applied by the sealing block 72, thereby improving the discharge speed of the lubricating oil in the oil storage tank 71 and increasing the lubricating oil addition efficiency.

[0032] In the technical solution provided by the present invention, the driving mechanism is an electric push rod 76 that is fixedly installed on the top of the oil storage tank 71 and can be vertically extended and retracted. The telescopic end of the electric push rod 76 passes through the oil storage tank 71 and extends into the inner cavity of the oil storage tank 71 and is fixedly connected to the sealing block 72.

[0033] When lubricating oil is added to the oil inlet of the oil storage tank 71, the lubricating oil first moves to the position above the sealing block 72, and then enters the position below the sealing block 72 through the one-way valve 75. The oil inlet speed is relatively slow. In the embodiment of the present invention, the one-way valve 75 is located directly below the oil inlet. When the lubricating oil enters the position above the sealing block 72 through the oil inlet, since the oil inlet is directly opposite the one-way valve 75, the lubricating oil impacts the one-way valve 75 during the oil inlet process, which can make the lubricating oil enter the position below the sealing block 72 more quickly, thereby increasing the oil inlet speed.

[0034] To ensure that a large amount of lubricating oil in the oil storage tank 71 can be discharged through the oil outlet pipe 74, and to prevent excessive lubricating oil residue at the bottom of the oil storage tank's inner cavity, in this embodiment of the invention, the bottom of the inner cavity of the oil storage tank 71 is a sloped structure, which is close to the oil outlet pipe 74 and inclined downwards. Utilizing the sloped structure, the lubricating oil, under its own gravity, can converge to the upper part of the oil outlet pipe 74 and be discharged, effectively preventing excessive lubricating oil residue in the inner cavity of the oil storage tank 71.

[0035] Lubricating oil is added directly by opening the oil outlet pipe 74 through the control valve 73. However, the amount of lubricating oil added is not easily discernible, and it is easy to add too much or too little lubricating oil. In this embodiment of the invention, a sensor for detecting the remaining lubricating oil level is provided on the inner wall of the oil storage tank. The output terminal of the sensor is electrically connected to the input terminal of the controller. After the sensor detects a signal, it transmits the signal to the controller 2. The controller 2 analyzes the transmitted signal to detect the remaining lubricating oil level.

[0036] It should be noted that the specific implementation of the sensor is not limited. It can be used to reflect the remaining amount of lubricating oil in the oil storage tank 71 by measuring the hydraulic pressure, or it can be used to reflect the remaining amount of lubricating oil in the oil storage tank 71 by measuring the change in liquid level, etc., and is not limited here.

[0037] Specifically, in the technical solution of the present invention, the sensor is a ranging sensor used to measure the moving distance of the sealing block. The ranging sensor is located above the sealing block, and specifically, it is a laser ranging sensor. When lubricating oil is added to the motor bearing through the oil tank 71, the sealing block 72 and the inner wall of the oil tank 71 form a sealed space, making it difficult for the lubricating oil in the inner cavity of the oil tank 71 to flow out under atmospheric pressure. When the sealing block 72 is pushed downward, the lubricating oil will move downward under the force applied by the sealing block 72. The amount added is proportional to the displacement of the sealing block 72. After the lubricating oil is added, the ranging sensor can measure the change in the displacement distance of the sealing block 72 to know the amount of lubricating oil added, which facilitates the determination of the amount of lubricating oil added.

[0038] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made under the concept of the present invention using the contents of the present invention specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A near-long-range early warning system for insufficient lubricating oil in motor bearings, characterized in that, The near- and long-range early warning system for insufficient lubricating oil in motor bearings includes: A vibration sensor is used to detect vibration signals generated when a motor bearing is running, the vibration signals including a vibration acceleration spectrum; monitor; Alarm; The first counter; and, The controller has its output electrically connected to the alarm, two fault location indicator lights, and a first counter, and its input electrically connected to the output of the vibration sensor. The controller determines that the motor bearing lubricating oil is insufficient when it receives a high-frequency vibration signal. The high-frequency vibration signal is a vibration signal in the vibration acceleration spectrum above 2kHz that exhibits a weed-like phenomenon. The controller then controls the display to issue an alarm. After the motor bearing is replenished with lubricating oil, the controller controls the first counter to start counting until the next high-frequency vibration signal is received, recording the time interval x. If x is less than or equal to a set value a, the controller determines it as a first fault and displays it on the display, indicating that the lubricating oil has not reached the bearing lubrication point. If x is greater than a but less than or equal to a set value b, the controller determines it as a second fault and displays it on the display, indicating that the lubricating oil quality has deteriorated. If x is greater than the set value b, the lubricating oil deficiency is considered normal consumption.

2. The near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 1, characterized in that, It also includes a second counter and a lubricating oil adding device electrically connected to the controller. After the motor bearing is replenished with lubricating oil, the controller controls the second counter to start timing and records the elapsed time as y. If y equals the set value m, it means that the lubricating oil in the motor bearing has reached the set usage time and needs to be added, and this is displayed on the display. After the lubricating oil adding device adds lubricating oil to the motor bearing, the controller controls the second counter to reset the measured time y to zero, and displays it on the display and restarts the timing.

3. The near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 1, characterized in that, The controller's output is electrically connected to a third counter. After the motor bearing is disassembled, cleaned, and re-lubricated, the controller controls the third counter to measure the total time z of the motor bearing after reinstallation and lubrication. When time z equals the set value n, it indicates that the total lubricating oil usage time of the motor bearing has reached the set value and needs to be completely replaced, and this is displayed on the display. After the motor bearing is disassembled, cleaned, and re-lubricated, the controller controls the total time z measured by the third counter to be reset to zero, and this is displayed on the display and the timing restarts.

4. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 2, characterized in that, The lubricating oil adding device includes an oil storage tank with an oil inlet vertically opened at the top, an oil outlet pipe connected to the bottom end of the oil storage tank, the bottom end of the oil outlet pipe connected to the oil inlet of the motor bearing, and a control valve for controlling its on and off is provided on it, the control valve being electrically connected to the controller.

5. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 4, characterized in that, The inner cavity of the oil storage tank is equipped with a sealing block that can slide vertically. The top of the sealing block is fixedly connected to a drive mechanism that controls its up and down movement. The sealing block is equipped with a one-way valve that is vertically downward and opens in one direction.

6. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 5, characterized in that, The driving mechanism is an electric push rod that is fixedly installed on the top of the oil storage tank and can be vertically extended and retracted. The telescopic end of the electric push rod passes through the oil storage tank and extends into the inner cavity of the oil storage tank, where it is fixedly connected to the sealing block.

7. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 5, characterized in that, The one-way valve is located directly below the oil inlet.

8. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 5, characterized in that, The bottom of the inner cavity of the oil storage tank is a sloping structure, which is close to the oil outlet pipe and is inclined downward.

9. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 8, characterized in that, The inner wall of the oil storage tank is equipped with a sensor for detecting the remaining amount of lubricating oil, and the output end of the sensor is electrically connected to the input end of the controller.

10. A near-long-range early warning system for insufficient lubricating oil in motor bearings as described in claim 9, characterized in that, The sensor is a distance measuring sensor used to measure the moving distance of the sealing block, and the distance measuring sensor is located above the sealing block.

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