Lubrication system control method

Abstract

The present application belongs to the technical field of engineering machinery, and particularly relates to a lubricating system control method, comprising: first oil injection lubrication process: setting automatic lubrication cycle and interval according to lubricating system pipeline length and total volume of lubricating pipeline, and automatically carrying out oil line filling exhaust through continuous starting of the lubricating system; simultaneously, automatically determining standard single lubrication cycle time reference value; regular lubrication process: comparing and calculating standard preset parameters with actual working condition collection data, and automatically adjusting system standard setting pressure of the lubricating system to keep single lubrication cycle actual operation time of the system within a set range; fault self-checking process: opening the lubricating circuit according to set lubricating circuit grouping rules, and taking pressure signal and single lubrication cycle time as reference to judge lubricating system fault point and fault type. The present application improves working condition environment temperature adaptability and reliability of the lubricating system, guarantees lubricating effect, and improves fault troubleshooting efficiency and lubricating system delivery debugging efficiency.

Description

Technical Field

[0001] This invention belongs to the field of engineering machinery technology, and specifically relates to a lubrication system control method. Background Technology

[0002] Lubrication systems are a crucial component of construction machinery, especially for equipment operating under complex and variable conditions and harsh environments. Real-time and effective lubrication of friction points such as slewing bearings and pins is key to ensuring the long-term stable operation of the equipment.

[0003] Existing equipment lubrication methods include manual grease gun application, which is labor-intensive and time-consuming. Therefore, existing equipment has gradually incorporated centralized lubrication systems. A typical centralized lubrication system includes a lubrication pump, distributor, and lubrication piping. The lubrication pump is equipped with pressure and oil level sensors. The system controls lubrication by controlling the power supply to the lubrication pump. When the pressure sensor issues a pressure alarm signal, the system considers one lubrication cycle complete and stops lubrication. While electronically controlled automatic lubrication improves efficiency, it has poor adaptability to harsh operating conditions. For example, in cold environments where grease viscosity increases and flow is poor, grease often cannot be injected into the final lubrication point within a lubrication cycle, leading to lubrication failure. To address this issue, patents such as CN110307965A and CN210687739U have addressed the lubrication effect assessment problem to some extent by adding grease flow detection devices and end-of-line detection devices to the lubrication system. However, this also significantly increases system complexity, introduces potential failure points, and increases system cost. Furthermore, before the equipment's lubrication system leaves the factory, it requires manual operation or prolonged operation to fill the lubrication lines with grease and purge air gaps to ensure effective lubrication after the equipment leaves the factory. This process is time-consuming, labor-intensive, and cannot guarantee effectiveness. Equipment with many lubrication points or large-sized equipment has numerous lubrication circuits and long lubrication lines, making troubleshooting difficult and inefficient when malfunctions occur. Summary of the Invention

[0004] The purpose of this invention is to solve the problems in the prior art and propose a lubrication system control method to improve the adaptability and reliability of the lubrication system to the ambient temperature, ensure the lubrication effect, and improve the efficiency of fault diagnosis and the factory commissioning efficiency of the lubrication system.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A lubrication system control method, comprising the following:

[0007] Initial lubrication control process: The automatic lubrication cycle and interval are set according to the length and total volume of the lubrication system pipeline. The lubrication system is continuously started to automatically fill and vent the oil circuit. At the same time, the standard single lubrication cycle time reference value is automatically measured.

[0008] Conventional lubrication control process: The standard preset parameters are compared and calculated with the data collected under actual working conditions, and the standard set pressure of the lubrication system is automatically adjusted to keep the actual running time of a single lubrication cycle within the set range.

[0009] Fault self-diagnosis process: Open the lubrication circuit according to the set lubrication circuit grouping rules, and use the detection pressure signal and single lubrication cycle time as a reference to determine the fault point and fault type of the lubrication system.

[0010] According to the lubrication system control method of the present invention, further, during the initial lubrication, the system standard set pressure P is first set. set The system sets the standard temperature temp1, the first oil injection cycle running time t1, and the time interval t2 between multiple first oil injection cycles, and then automatically injects oil and vents air into the lubrication pipeline according to t1 and t2.

[0011] According to the lubrication system control method of the present invention, further, during the oil injection process, when the system pressure reaches the system standard set pressure P... set Stop the initial lubrication cycle and manually check the end of each lubrication circuit for any lubricating oil leakage. If no leakage occurs, repeat the above process. If leakage occurs, start n regular lubrication cycles, and simultaneously calculate and store the system's set standard time t for a single lubrication cycle. set .

[0012] According to the lubrication system control method of the present invention, the initial oil injection cycle time t1 is further set proportionally to the total volume of the lubrication pipeline, and the calculation formula is as follows:

[0013] t1 = V1 / V2 / 1000 (min)

[0014] In the formula, V1 represents the total volume of the lubrication pipeline, and V2 represents the oil output of a single lubrication cycle.

[0015] The time interval t2 between the multiple initial oil injection cycles is set proportionally to the length of the lubrication system pipeline, and the calculation formula is as follows:

[0016] t2=L max / (1-1.5)(min)

[0017] In the formula, L max This indicates the longest lubrication line.

[0018] According to the lubrication system control method of the present invention, further, during normal lubrication, after the lubrication system is powered on, the system standard setting pressure P is initialized. set The standard time t for a single lubrication cycle of the system is set. set At the system's set standard temperature temp1, perform one lubrication cycle and determine the actual running time t of a single lubrication cycle. real Is it greater than the maximum allowable time t for a single lubrication cycle in the system? limit If the system is determined to be faulty, it will proceed with a fault self-check process; otherwise, it will continue with subsequent procedures.

[0019] According to the lubrication system control method of the present invention, further, when t real ≤t limit Then, further determine the standard time t for a single lubrication cycle of the system. set The actual running time t of a single lubrication cycle of the system real Is the difference greater than the system's single lubrication cycle time difference threshold t? threshold When t real -t set >t threshold If the lubrication parameter adjustment process is initiated, the lubrication cycle will continue; otherwise, it will continue.

[0020] According to the lubrication system control method of the present invention, the lubrication parameter adjustment process is further as follows: It is determined whether the difference between the system set standard temperature temp1 and the system ambient temperature temp2 is greater than the temperature difference threshold temp3. When temp1-temp2>temp3, the system standard set pressure P is adjusted. set With system pressure regulation variable P step Increase the step size until P set Equal to the system's maximum allowable pressure P max If the adjusted P set equals P max It is not yet possible to make t real- t set ≤t threshold Then it enters the fault self-check process; when temp1-temp2≤temp3, the lubrication cycle continues.

[0021] According to the lubrication system control method of the present invention, the fault self-check process is further as follows:

[0022] First, close the main circuit solenoid valve at the lubrication pump outlet and execute one lubrication cycle. If the system pressure quickly reaches P... set If the problem is resolved, then troubleshooting of other circuits should continue.

[0023] According to the set lubrication circuit grouping rules, one group of lubrication circuits is opened, and the solenoid valves of other circuits are closed. Each time, half of the solenoid valves are closed, and one lubrication process is executed. There are two possible scenarios: Scenario 1, if t real >t limit If there is no pressure feedback for a long time, there is a fault in the lubrication line, the pressure sensor is damaged, or the oil level sensor is damaged. In the second case, if there is pressure feedback but there is no leakage at the end of the lubrication circuit, there is a fault in the corresponding circuit line being blocked / squeezed or the corresponding circuit oil outlet being blocked.

[0024] Perform the above steps for each lubrication circuit according to the grouping rules until the fault point and fault information are found.

[0025] Compared with the prior art, the present invention has the following advantages:

[0026] 1. In this invention, when the difference between the system's set standard temperature and the system's ambient temperature exceeds a temperature difference threshold, the system's standard set pressure P is adjusted. set Make an upward adjustment; if P is adjusted accordingly... set Equal to the system's maximum allowable pressure P max It is not yet possible to make t real -t set ≤t threshold Then it enters the fault self-check process; by adjusting the standard pressure setting of the system, the flow rate of the lubricating oil can be accelerated so that it can reach the lubrication point, thereby improving the adaptability and reliability of the lubrication system under working conditions.

[0027] 2. This invention sets the automatic lubrication cycle and interval according to the length of the lubrication system pipeline and the total volume of the lubrication pipeline, so as to realize the automatic oil injection and air venting operation of the lubrication pipeline. Compared with the traditional manual oil injection and air venting, this invention improves the factory commissioning efficiency of the lubrication system.

[0028] 3. This invention implements specific opening and closing control methods for each lubrication circuit, using the detection pressure signal and the time of a single lubrication cycle as references, to determine the fault point and fault type of the lubrication system, thereby improving the efficiency of fault location and troubleshooting. Attached Figure Description

[0029] 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 these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the initial oil injection lubrication control process according to an embodiment of the present invention;

[0031] Figure 2 This is a schematic diagram of a conventional lubrication control process according to an embodiment of the present invention;

[0032] Figure 3 This is a schematic diagram of the fault self-test process according to an embodiment of the present invention. Detailed Implementation

[0033] 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 some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] The lubrication system control method in this embodiment is based on a control system, which includes a lubrication pump, pressure sensor, oil level sensor, temperature sensor, main controller, display, pressure relief solenoid valve, on / off solenoid valves for each lubrication circuit, and lubrication pipelines. The parameter symbols appearing in this document are explained below.

[0035] A lubrication cycle is defined as follows: The lubrication pump is started, and it discharges lubricating oil from the oil tank into the lubrication pipeline. At the end of the pipeline, an injector gradually injects lubricating oil into the lubrication points as the pressure in the pipeline gradually increases. The lubrication cycle continues until the pressure in the pipeline reaches the system's standard set pressure P. set When the lubrication pump stops, one lubrication cycle is completed.

[0036] The system's maximum permissible pressure P max This is the pressure value for safe operation of the lubrication system. If the pressure inside the lubrication pipeline exceeds this value for an extended period, it may damage the lubrication pump.

[0037] System standard set pressure P set This value is less than the system's maximum allowable pressure P. max Changing this value can affect the time of a single lubrication cycle and the lubrication effect.

[0038] System pressure regulation variable P step Adjust the system standard setting pressure P set The step size parameter.

[0039] The system set standard temperature temp1 generally refers to the ambient temperature of the lubrication system during factory commissioning.

[0040] System ambient temperature temp2: This generally refers to the ambient temperature of the lubrication system under actual operating conditions.

[0041] Temperature difference threshold temp3: This parameter determines whether the lubrication standard setting parameters need to be adjusted. When the difference between temp1 and temp2 is greater than this value, adjustment control is triggered.

[0042] The standard time t for a single lubrication cycle of the system is set. set : This is obtained through the initial lubrication control process, that is, the average number of tests n under the factory commissioning environment of the lubrication system.

[0043] The actual running time t of a single lubrication cycle of the system real : The time of a single lubrication cycle under actual lubrication application conditions.

[0044] System single lubrication cycle time difference threshold t threshold : Determine the parameters that need adjustment to the lubrication standard setting parameters, when t set With t real When the difference is greater than this value, adjustment control is triggered.

[0045] Maximum permissible time t for a single lubrication cycle in the system limit When the lubrication cycle time of a single lubrication cycle exceeds this parameter, it is determined that there is a fault in the lubrication system, and the lubrication process is automatically stopped to trigger an alarm and perform a fault self-check.

[0046] The initial oil injection cycle time t1 is a time parameter determined based on the total volume of the lubrication pipeline and the amount of oil dispensed in one lubrication cycle. Proper setting of this parameter will improve the efficiency of automatic oil injection. The "initial oil injection cycle" mentioned here is different from "one lubrication cycle" mentioned above. One initial oil injection cycle does not reach the system's standard set pressure; multiple initial oil injection cycles are required for the lubrication system to reach the system's standard set pressure.

[0047] Time interval t2 between multiple initial oil filling cycles: Since multiple initial oil filling cycles are required to achieve the functional requirement of filling the lubrication pipeline with lubricating oil, there may be air or blockage in the pipeline before it is filled. In addition, the lubricating oil itself has a certain viscosity and needs a certain buffer to achieve the effect of full filling. This time parameter is related to the length of the lubrication system pipeline.

[0048] The number of tests n is set after the initial run reaches the set pressure and completes one cycle. The standard time t is set to accurately measure the system's single lubrication cycle. set Run the test multiple times and take the average value, which ranges from 3 to 5.

[0049] Total volume of lubrication pipeline V1: The volume of all lubrication pipelines in the lubrication system, which is the volume of lubricating oil required to fill the entire pipeline.

[0050] Single lubrication volume output V2: The volume of oil output from the end of the lubrication pipeline when starting a lubrication cycle.

[0051] Longest lubrication line L max : The longest value in the lubrication system pipeline, in meters.

[0052] The lubrication system control method in this embodiment mainly includes the following three control processes.

[0053] Initial lubrication control process: The automatic lubrication cycle and interval are set according to the length and total volume of the lubrication system pipeline. The lubrication system is continuously started to automatically fill and vent the oil circuit. At the same time, the standard single lubrication cycle time reference value is automatically measured to improve the efficiency of the lubrication system's factory commissioning.

[0054] Conventional lubrication control process: The standard preset parameters are compared and calculated with the data collected under actual working conditions. The standard set pressure of the lubrication system is automatically adjusted so that the actual running time of a single lubrication cycle is kept within the set range, achieving rapid and effective lubrication under low temperature conditions.

[0055] Fault self-diagnosis process: Open the lubrication circuit according to the set lubrication circuit grouping rules, and use the detection pressure signal and single lubrication cycle time as a reference to determine the fault point and fault type of the lubrication system.

[0056] (1) Initial oil injection lubrication control process (process as follows) Figure 1 (As shown)

[0057] The initial lubrication control refers to the first operation of the lubrication system after the equipment with the lubrication system is off the production line. During this stage, the lubrication pipeline is in a state of no lubricating oil, and it is necessary to manually fill the oil line with an oil gun. This process is time-consuming and labor-intensive and cannot guarantee that the pipeline is filled. Therefore, this embodiment proposes an automatic oil injection and air venting method.

[0058] First, set the system standard set pressure P. set The system sets a standard temperature temp1, an initial oil injection cycle time t1, and a time interval t2 between multiple initial oil injection cycles, and then automatically injects oil and vents air from the lubrication lines. The initial oil injection cycle time t1 is set proportionally to the total volume of the lubrication lines, and the calculation formula is as follows:

[0059] t1 = V1 / V2 / 1000 (min)

[0060] The time interval t2 between multiple initial oil injection cycles is set proportionally to the length of the lubrication system pipeline, and the calculation formula is as follows:

[0061] t2=L max / (1-1.5)(min).

[0062] During this stage, the maximum permissible time t for a single lubrication cycle of the system is... limitThis is not considered a fault signal. After multiple initial oil filling cycles according to t1 and t2, the lubrication lines will gradually be vented and filled with lubricating oil. Therefore, during the oil filling process, when the system pressure reaches the system standard set pressure P... set Stop the initial lubrication cycle. At this point, manually check the ends of each lubrication circuit for oil leakage. If no oil leakage is observed, repeat the above procedure. Once oil leakage is confirmed at the ends of all lubrication circuits, initiate n regular lubrication cycles, simultaneously calculating and storing the system's set standard time t for a single lubrication cycle. set This serves as the parameter input for the subsequent routine lubrication control process.

[0063] (2) Conventional lubrication control process (process as follows) Figure 2 (As shown)

[0064] This process mainly refers to the control methods and operating procedures of the lubrication system under actual operating conditions. After the lubrication system is powered on, it initializes the system's standard set pressure P. set The standard time t for a single lubrication cycle of the system is set. set At the system's set standard temperature temp1, perform one lubrication cycle and determine the actual running time t of a single lubrication cycle. real Is it greater than the maximum allowable time t for a single lubrication cycle in the system? limit If the system is determined to be faulty, it will proceed with a fault self-check process; otherwise, it will continue with subsequent procedures.

[0065] Continue executing the process and determine the standard time t for a single lubrication cycle of the system. set The actual running time t of a single lubrication cycle of the system real Is the difference greater than the system's single lubrication cycle time difference threshold t? threshold When t real -t set >t threshold If the lubrication parameter adjustment process is initiated, the lubrication cycle will continue; otherwise, it will continue.

[0066] Further determine whether the difference between the system's set standard temperature temp1 and the system's ambient temperature temp2 is greater than the temperature difference threshold temp3. If temp1 - temp2 > temp3, execute the adjustment of the system's standard set pressure P. set With system pressure regulation variable P step Increase the step size until P set Equal to the system's maximum allowable pressure P max If the adjusted P set equals P max It is not yet possible to make t real -t set ≤t thresholdIf an alarm is triggered, the fault self-check process will begin; if temp1-temp2≤temp3, the lubrication cycle will continue.

[0067] It should be noted that the automatically adjusted P set Stored and recalled only during a single power-on cycle of the lubrication system; after the lubrication system (i.e., the equipment on which the lubrication system is installed) is powered off and then powered on again, P... set Initialize to the original value. The automatic control method uses temperature, the main factor affecting lubricating oil viscosity, as the criterion for adjusting P. set Through the adjusted P set It can accelerate the flow of lubricating oil in pipelines, thereby ensuring the lubrication efficiency and lubrication effect of the lubrication system in low-temperature environments.

[0068] (3) Fault self-test process (process as follows) Figure 3 (As shown)

[0069] During system initialization, the lubrication system circuits are classified and marked according to their installation positions on the equipment, based on the set grouping and classification rules. The main controller of the control system records the control I / O of the solenoid valves of each lubrication circuit.

[0070] When performing a fault self-check, first close the main circuit solenoid valve at the lubrication pump outlet and execute one lubrication cycle. If the system pressure quickly reaches P... set If the problem is resolved by eliminating the lubrication pump, proceed with troubleshooting other circuits. Specifically, a program can be used to close half of the solenoid valves in each circuit at a time, thus eliminating half of the potential faults in a single operation and improving troubleshooting efficiency. The details are as follows:

[0071] Step S101: According to the set lubrication circuit grouping rules, open one group of lubrication circuits, close the solenoid valves of other circuits, and execute one lubrication process. There are two possible scenarios.

[0072] Case 1, if t real >t limit If there is no pressure feedback for an extended period, the following faults may exist:

[0073] ① There is a leak in the lubrication line, which prevents pressure from being built up, causing the lubrication system to remain in a lubrication execution state.

[0074] ② The pressure sensor is damaged and cannot detect the end of a lubrication cycle (system pressure reaches P). set ).

[0075] ③ The oil level sensor is damaged and cannot detect the absence of oil, causing the system to be unable to build up pressure and remain in the lubrication execution state.

[0076] Scenario 2: If there is pressure feedback but no leakage at the end of the lubrication circuit, the following faults may exist:

[0077] ① The corresponding circuit pipeline is blocked or squeezed.

[0078] ②The oil outlet of the corresponding circuit is blocked.

[0079] Step S102: Perform step S101 separately for each lubrication circuit according to the grouping rules until the fault point and fault information are found, which serve as fault indications to guide manual fault handling.

[0080] The lubrication system control method proposed in this invention can effectively improve the temperature adaptability of the lubrication system under operating conditions without the need for additional complex testing methods, thus reducing costs. It also improves the efficiency of factory commissioning and fault diagnosis of the lubrication system.

[0081] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code. The solutions in the embodiments of the present invention can be implemented using various computer languages, such as the object-oriented programming language Java and the interpreted scripting language JavaScript.

[0082] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0083] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0084] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A lubrication system control method, characterized in that, Includes the following: Initial lubrication control procedure: Based on the length and total volume of the lubrication system piping, the automatic lubrication cycle and interval are set. The lubrication system is continuously started to automatically fill and vent the oil circuit. Simultaneously, the standard single lubrication cycle time reference value is automatically measured. During the initial lubrication, the system's standard set pressure P is first set. set The system sets the standard temperature temp1, the first oil injection cycle running time t1, and the time interval between multiple first oil injection cycles t2, and then automatically injects oil and vents air in the lubrication pipeline according to t1 and t2. During the oil injection process, when the system pressure reaches the system standard set pressure P set Stop the initial lubrication cycle and manually check the end of each lubrication circuit for any lubricating oil leakage. If no leakage occurs, repeat the above process. If leakage occurs, start n regular lubrication cycles, and simultaneously calculate and store the system's set standard time t for a single lubrication cycle. set ; Routine lubrication control procedure: The standard preset parameters are compared and calculated with data collected under actual operating conditions. The system's standard set pressure is automatically adjusted to keep the actual running time of a single lubrication cycle within the set range. During routine lubrication, the system's standard set pressure P is initialized after power-on. set The standard time t for a single lubrication cycle of the system is set. set At the system's set standard temperature temp1, perform one lubrication cycle and determine the actual running time t of a single lubrication cycle. real Is it greater than the maximum allowable time t for a single lubrication cycle in the system? limit If a fault is detected in the lubrication system, the system will proceed with a self-check process; otherwise, the system will continue with subsequent steps. real ≤t limit Then, further determine the standard time t for a single lubrication cycle of the system. set The actual running time t of a single lubrication cycle of the system real Is the difference greater than the system's single lubrication cycle time difference threshold t? threshold When t real -t set >t threshold If the system enters the lubrication parameter adjustment process, it will proceed; otherwise, the lubrication cycle will continue. The lubrication parameter adjustment process is as follows: determine whether the difference between the system set standard temperature temp1 and the system ambient temperature temp2 is greater than the temperature difference threshold temp3. If temp1-temp2>temp3, adjust the system standard set pressure P. set With system pressure regulation variable P step Increase the step size until P set Equal to the system's maximum allowable pressure P max If the adjusted P set equals P max It is not yet possible to make t real- t set ≤t threshold Then the fault self-check process will begin; when temp1-temp2≤temp3, the lubrication cycle will continue. Fault self-diagnosis process: Open the lubrication circuit according to the set lubrication circuit grouping rules, and use the detection pressure signal and single lubrication cycle time as a reference to determine the fault point and fault type of the lubrication system.

2. The lubrication system control method according to claim 1, characterized in that, The specific fault self-diagnosis process is as follows: First, close the main circuit solenoid valve at the lubrication pump outlet and execute one lubrication cycle. If the system pressure quickly reaches P... set If the problem is resolved, then troubleshooting of other circuits should continue. According to the set lubrication circuit grouping rules, one group of lubrication circuits is opened, and the solenoid valves of other circuits are closed. Each time, half of the solenoid valves are closed, and one lubrication process is executed. There are two possible scenarios: Scenario 1, if t real >t limit If there is no pressure feedback for a long time, there is a fault in the lubrication line, the pressure sensor is damaged, or the oil level sensor is damaged. In the second case, if there is pressure feedback but there is no leakage at the end of the lubrication circuit, there is a fault in the corresponding circuit line being blocked / squeezed or the corresponding circuit oil outlet being blocked. Perform the above steps for each lubrication circuit group according to the lubrication circuit grouping rules until the fault point and fault information are found.

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