A method for monitoring the operating status of a micro lubricator

Abstract

The present invention relates to the technical field of micro-lubricator monitoring, and in particular to a method for monitoring the operating status of a micro-lubricator. According to the characteristics of the periodic operation of the micro-lubricator, a standard operation curve diagram is drawn and different current monitoring thresholds are set. The current model of the lubricator during operation is compared with the standard model to infer the type of lubricator failure. The method comprises the following steps: micro-lubricator operation, monitoring threshold setting and current monitoring. The method determines the cause of the failure of the micro-lubricator by monitoring the change of current, improves the detection accuracy, reduces the modification of the inside of the micro-lubricator, reduces the failure rate of the micro-lubricator, and reduces the monitoring cost of the operating status of the micro-lubricator.

Description

Technical Field

[0001] The invention relates to the technical field of micro lubricator monitoring, and in particular to a method for monitoring the operating status of a micro lubricator. Background Art

[0002] The rotation of the equipment requires the support of bearings. Rolling bearings need to be regularly filled with grease to maintain the oil film on the raceway. Traditional grease filling is divided into manual regular grease filling and centralized lubrication and grease supply. Centralized lubrication and grease supply are mainly for equipment with relatively concentrated lubrication points. For dispersed lubrication points, companies still adopt manual regular grease filling, which is time-consuming and labor-intensive, so micro lubricators have emerged.

[0003] The existing micro-lubricator is a small and exquisite mechanical device, which is mainly used to provide the required micro-lubrication during the operation of mechanical equipment, and can realize automatic filling and remote control of grease.

[0004] However, it was found during use that existing lubricators, such as the portable grease dispersing filling device disclosed in the invention patent with publication number CN112196986B and the multi-point automatic greaser disclosed in the utility model patent with publication number CN202074211U, can all realize grease filling, but it is not convenient to monitor the operating status of the greaser. Although some greasers can determine the motor operating status by receiving signals from photoelectric switches or magnetic switches, they can only determine problems with the equipment itself. However, for excessive back pressure caused by lubrication point failure or other problems, it is impossible to determine whether it is a motor failure or a photoelectric switch or magnetic switch that does not receive a signal due to excessive pipeline back pressure, resulting in poor practicality. Therefore, a method for monitoring the operating status of a micro lubricator is urgently needed. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides a method for monitoring the operating status of a micro-lubricator, which can determine the cause of failure of the micro-lubricator by monitoring the change of current, improve the detection accuracy, reduce the modification of the inside of the micro-lubricator, reduce the failure rate of the micro-lubricator, and reduce the monitoring cost of the operating status of the micro-lubricator.

[0006] A method for monitoring the operation status of a micro lubricator of the present invention draws a standard operation curve diagram and sets different current monitoring thresholds according to the characteristics of the periodic operation of the micro lubricator, compares the current model of the lubricator during operation with the standard model, and infers the type of lubricator fault, including the following steps:

[0007] S1. Operation of the micro lubricator: The battery supplies power to the motor regularly according to the established time program. After the motor is powered on, it drives the driving gear set to drive the cam to move. The cam pushes the shift fork in contact with it, and then the shift fork drives the hollow plunger to move upward. A second spring is pressed on the hollow plunger, and the second spring is squeezed. When the cam reaches the highest point through circular motion, it disengages from the shift fork. Under the action of the squeezed second spring, the shift fork drives the hollow plunger to move downward rapidly. During the upward movement of the hollow plunger, the grease in the upper cavity is squeezed into the oil leakage column. During the downward movement of the hollow plunger, the grease in the oil leakage column is ejected, and a vacuum is formed in the upper cavity. When the oil bag is connected to the top of the hollow plunger, the grease in the oil bag is sucked into the upper cavity to prepare for the next grease injection.

[0008] S2, monitoring threshold setting: according to the operating voltage of the motor, set the current at the maximum current two seconds before the idling of the driving gear set, and set the maximum current when the cam pushes the shift fork to compress the second spring to do work;

[0009] S3. Current monitoring: After the program is started, the current of the electronic control unit is monitored according to the threshold value. According to the monitoring results, different fault codes are used to prompt the staff.

[0010] Preferably, the driving gear set is a four-stage double gear for speed reduction, and the reduction ratio is 1100, and the motor speed is reduced and the torque is increased through the large reduction ratio.

[0011] Preferably, the current monitoring method comprises the following steps:

[0012] S3.1. After the program is started, the shift fork is at a certain position, the electronic control unit has current output, and the maximum operating current in the first six seconds is continuously higher than the preset maximum current by more than 1.5 times. At this time, it can be considered that the motor is faulty or the drive gear set is stuck, and the corresponding fault code E01 is prompted;

[0013] S3.2, after the program is started, the shift fork is at a certain position, the electronic control unit has current output, and in the first half of two seconds, it runs at the preset idling current of the drive gear set, the running current does not increase significantly, and the maximum running current is less than half of the preset maximum current. In the second half, the current increases, and the maximum current is less than the preset maximum current. At this time, it can be considered that the motor has no fault, and the shift fork starts to be forced from the middle part to push the second spring to compress and work. It is considered that there is a pipeline oil blockage fault at this time, and the corresponding fault code E02 can be prompted;

[0014] S3.3, after the program is started, the shift fork is at a certain position. Within the first six seconds, the electronic control unit has current output, but the operating current runs at the preset no-load current of the drive gear set. It is considered that the drive gear set is disconnected from the motor at this time, and the motor has an idling fault, prompting the corresponding fault code E03;

[0015] S3.4: After the program is started, the shift fork is at a certain position. Within the first six seconds, the electronic control unit has no current output. At this time, it is considered that the motor power line is disconnected and the corresponding fault code E04 is prompted.

[0016] Preferably, the micro-lubricator is provided with a control panel and an indicator light, and the control panel is provided with a display screen, and the fault code is displayed through the display screen on the control panel, and the indicator light flashes to remind the staff.

[0017] Preferably, the current monitoring process can be operated manually, or the data can be sent to the cloud via wireless communication, and the cloud program will make a judgment. When the cloud determines that the data exceeds a set threshold, an alarm will be sent back to the control panel or electronic control board of the micro lubricator.

[0018] Preferably, during the current monitoring process, the micro-lubricator is in normal working condition, a complete working cycle does not exceed ten seconds, and it is a periodic operation to prevent the electronic control program from being disordered and continuously running. The total running time is added to the program to constrain the program so that the program stops working after the time is reached.

[0019] Preferably, the electronic control program can trigger the operation of the lubricator according to an external timer or other sensors in addition to running regularly according to its own timer.

[0020] Preferably, the micro-lubricator includes a first shell, a second shell, a first bracket, a second bracket, a fixed plate, a third bracket, a first spring, a first support plate, an oil bag, a second support plate, a hollow plunger, a driving gear set, a motor, a shift fork, a second spring, two sets of cams and an oil leakage column. The second shell is mounted on the first shell, the first bracket and the second bracket are both mounted inside the first shell, the fixed plate is mounted on the first shell, the first spring is mounted on the first bracket, the first spring is mounted inside the second shell, the first support plate is mounted on the bottom of the first spring, the oil bag is mounted on the second bracket through the second support plate, and a one-way valve is provided at the bottom of the oil bag, the hollow plunger is slidably mounted in the middle of the second shell, the oil leakage column is mounted at the bottom of the hollow plunger, and the driving gear set is mounted on the third support plate. The motor is fixedly mounted on the third bracket, and the output end of the motor is meshed and connected with the rear part of the driving gear set, one end of the shift fork is rotatably mounted on the third bracket, the second spring is sleeved on the hollow plunger, and the top end of the second spring is clamped on the second bracket, the other end of the shift fork is clamped on the hollow plunger, and the two sets of cams are rotatably mounted on the front part of the driving gear set; the oil bag is squeezed downward by the elasticity of the first spring, and the motor is turned on, so that the driving gear set drives the two sets of cams to rotate, and the other end of the shift fork is squeezed by the rotating two sets of cams, so that when the shift fork drives the hollow plunger to move upward, the grease in the oil bag enters the hollow plunger, and after the cam passes the other end of the shift fork, the hollow plunger moves downward by the elasticity of the second spring, and the grease inside the oil leakage column is sprayed out through the hollow plunger.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. By monitoring the change of current, the cause of the failure of the micro-lubricator can be determined, the detection accuracy can be improved, and the modification of the internal part of the micro-lubricator can be reduced and simplified, the failure rate of the micro-lubricator can be reduced, and the monitoring cost of the operating status of the micro-lubricator can be reduced;

[0023] 2. During the monitoring process, judgment can be made through manual or cloud programs to improve applicability;

[0024] 3. The driving gear set adopts four-stage double gears to achieve large motor deceleration and greater torque improvement. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a flow chart of the method for monitoring the operating status of a micro lubricator of the present invention.

[0026] Figure 2 It is a schematic diagram of the axial structure of the micro lubricator of the present invention.

[0027] Figure 3 It is a schematic diagram of the exploded structure of the micro lubricator of the present invention.

[0028] Figure 4 It is a schematic diagram of the enlarged structure of the first axis side of the motor, the shift fork, the second spring and other structures of the present invention.

[0029] Figure 5 It is a schematic diagram of the enlarged structure of the second axis side of the motor, shift fork, second spring and other structures of the present invention.

[0030] Figure 6 It is a schematic diagram of the first shaft side enlarged structure of the drive gear set, motor, shift fork and other structures of the present invention.

[0031] Figure 7 It is a schematic diagram of the second shaft side enlarged structure of the drive gear set, motor, shift fork and other structures of the present invention.

[0032] Figure 8 It is a schematic diagram of the stall acquisition circuit of the motor drive and electronic control processing electrical principle diagram of the present invention.

[0033] Fig. 9 It is a schematic diagram of the relationship between the current and the running time of the motor of the present invention in a single cycle at a voltage of 4.5V.

[0034] Fig.10 It is a schematic diagram of the relationship between the current and the running time in a single cycle of the invented motor under the voltage of 4.5V and the hollow cup motor.

[0035] Markings in the accompanying drawings: 1. first housing; 2. second housing; 3. first bracket; 4. second bracket; 5. fixing plate; 6. third bracket; 7. first spring; 8. first support plate; 9. oil bag; 10. second support plate; 11. hollow plunger; 12. driving gear set; 13. motor; 14. shift fork; 15. second spring; 16. cam; 17. oil leakage column. DETAILED DESCRIPTION

[0036] In order to facilitate understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thorough and comprehensive.

[0037] Example

[0038] like Figures 1 to 10 As shown, a method for monitoring the operation status of a micro lubricator is provided. According to the characteristics of the periodic operation of the micro lubricator, a standard operation curve is drawn and different current monitoring thresholds are set. The current model of the lubricator during operation is compared with the standard model to infer the type of lubricator fault, including the following steps:

[0039] S1. Operation of the micro lubricator: The battery supplies power to the motor 13 at regular intervals according to a predetermined time program. After the motor 13 is powered on, it drives the driving gear set 12 to drive the cam 16 to move. The cam 16 pushes the fork 14 in contact with it, and then the fork 14 drives the hollow plunger 11 to move upward. A second spring 15 is pressed on the hollow plunger 11, and the second spring 15 is squeezed. When the cam 16 reaches the highest point through the circular motion, it disengages from the fork 14. Under the action of the squeezed second spring 15, the fork 14 drives the hollow plunger 11 to move downward rapidly. During the upward movement of the hollow plunger 11, the grease in the upper cavity is squeezed into the oil leakage column 17. During the downward movement of the hollow plunger 11, the grease in the oil leakage column 17 is ejected, and a vacuum is formed in the upper cavity. When the oil bag 9 is connected to the top of the hollow plunger 11, the grease in the oil bag 9 is sucked into the upper cavity to prepare for the next grease injection.

[0040] S2, monitoring threshold setting: when the motor 13 is working at a voltage of 4.5V, the current for the first two seconds when the driving gear set 12 is idling is about 90mA, and the maximum current when the cam 16 pushes the fork 14 to compress the second spring 15 to do work is about 400mA;

[0041] S3, current monitoring: including the following steps:

[0042] S3.1, if after the program is started, the shift fork 14 is at a certain position, the electronic control unit has current output, and the maximum operating current in the first six seconds is continuously higher than the preset maximum current (400mA) by more than 1.5 times, that is, the maximum current is higher than 1000mA, then it can be considered that the motor 13 is faulty or the drive gear set 12 is stuck, etc., and the corresponding fault code E01 is prompted;

[0043] S3.2, after the program is started, if the shift fork 14 is at a certain position, the electronic control unit has current output, and in the first half of two seconds, the motor 13 runs at 90mA, the running current does not increase significantly, and the maximum running current is less than 200mA, and the current increases in the second half, and the maximum current is less than 400mA, then it can be considered that the motor 13 has no fault, and the shift fork 14 is forced from the middle part to push the second spring 15 to compress and do work, then it can be considered that there is a pipeline oil blockage fault, and the corresponding fault code E02 can be prompted;

[0044] S3.3, if after the program is started, the shift fork 14 is at a certain position, within the first six seconds, the electronic control unit has current output, but the operating current is 90mA, it is considered that the drive gear set 12 is disconnected from the motor 13, and the motor 13 has an idling fault, and the corresponding fault code E03 is prompted;

[0045] S3.4. If the shift fork 14 is at a certain position after the program is started, and the electronic control unit has no current output within the first six seconds, that is, 0 mA, it is considered that the power line of the motor 13 is disconnected, and the corresponding fault code E04 is prompted.

[0046] During the current monitoring process, the micro-lubricator is in normal working state, and a complete working cycle does not exceed ten seconds, and it is a periodic operation. To prevent the electronic control program from being disordered and continuous, the total running time is added to the program to constrain the program so that it stops working after the program reaches the time. By monitoring the change in current, the cause of the micro-lubricator's failure can be determined, the detection accuracy can be improved, and the modification of the micro-lubricator's internal structure can be reduced, thereby reducing the failure rate of the micro-lubricator and reducing the cost of monitoring the operating status of the micro-lubricator.

[0047] The micro lubricator is provided with a control panel and an indicator light, and the control panel is provided with a display screen, and the fault code is displayed on the display screen of the control panel, and the indicator light flashes to remind the staff. The current monitoring process can be operated manually, or the data can be sent to the cloud through wireless communication, and the cloud program determines that when the cloud determines that the data exceeds the set threshold, an alarm is sent back to the control panel or electric control board of the micro lubricator.

[0048] During the current monitoring process, the micro lubricator is in normal working state, and a complete working cycle does not exceed ten seconds, and it is a periodic operation to prevent the electronic control program from being confused and continuous. The total running time is added to the program to constrain the program so that the program stops working after the time is reached. In addition to the timing operation of its own timer, the electronic control program can also trigger the operation of the lubricator according to an external timer or other sensors.

[0049] The micro lubricator comprises a first housing 1, a second housing 2, a first bracket 3, a second bracket 4, a fixing plate 5, a third bracket 6, a first spring 7, a first support plate 8, an oil bag 9, a second support plate 10, a hollow plunger 11, a driving gear set 12, a motor 13, a shift fork 14, a second spring 15, two groups of cams 16 and an oil leakage column 17. The second housing 2 is mounted on the first housing 1, the first bracket 3 and the second bracket 4 are both mounted inside the first housing 1, the fixing plate 5 is mounted on the first housing 1, the first spring 7 is mounted on the first bracket 3, the first spring 7 is mounted inside the second housing 2, the first support plate 8 is mounted on the bottom of the first spring 7, and the oil bag 9 passes through the second support plate 10 is mounted on the second bracket 4, and a one-way valve is provided at the bottom of the oil bag 9, the hollow plunger 11 is slidably mounted in the middle of the second housing 2, the oil leakage column 17 is mounted at the bottom of the hollow plunger 11, the driving gear set 12 is mounted on the third bracket 6, the motor 13 is fixedly mounted on the third bracket 6, and the output end of the motor 13 is meshed and connected with the rear of the driving gear set 12, one end of the fork 14 is rotatably mounted on the third bracket 6, the second spring 15 is sleeved on the hollow plunger 11, and the top end of the second spring 15 is clamped on the second bracket 4, the other end of the fork 14 is clamped on the hollow plunger 11, and the two sets of cams 16 are rotatably mounted on the front final gear of the driving gear set 12. The driving gear set 12 is a four-stage double gear for speed reduction, and the reduction ratio is 1100. The large reduction ratio is used to reduce the speed of the motor 13 and increase the torque.

[0050] like Figure 8 As shown, the motor M is directly powered by a 4.5V battery pack, the capacitor C8 is used for voltage stabilization and filtering to prevent voltage fluctuations, and the diode D1 is for reverse voltage protection; the addition of the optocoupler device U2 makes the control action more stable, and controls the MOS tube N2 to complete the power supply shutdown of the motor M; when the motor M is working, the current flowing through the resistor R27 forms a voltage difference, which enters the differential amplification formed by the amplifier U4, and the signal is amplified and output to the CPU through the resistor R3, and the data is processed after A / D conversion to complete the monitoring and control of the running status of the motor M.

[0051] like Fig. 9 As shown, it is a schematic diagram of the relationship between the current and the running time of the motor 13 in a single cycle under the ordinary 4.5V motor. Fig.10 As shown, it is a schematic diagram of the relationship between the current and the running time of the motor 13 in a single cycle under the ordinary 4.5V motor and the 4.5V hollow cup motor. The solid line in the figure is the ordinary 4.5V motor, and the dotted line in the figure is the 4.5V hollow cup motor.

[0052] Among them, the starting current of an ordinary 4.5V motor is about 70~100mA. Taking the average value of 90 mA as an example, the starting current is 90mA, the oil blockage alarm is set to 200mA, the maximum current is 400mA, and the stuck current is set to 1000mA.

[0053] Among them, the starting no-load current of the 4.5V hollow cup motor is about 20~40mA, the average is 30 mA, the starting current is 30mA, the oil blockage alarm is set to 150, the maximum current is 350 mA, and the stuck current is set to 800 mA or 1000 mA.

[0054] In summary, there will be differences in the starting no-load current of different types of motors, but the differences are small. The starting no-load current slightly fluctuates above and below the standard model and will not affect the overall trend. By setting different threshold parameters for different types of motors, the fault alarm parameters can be extracted.

[0055] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for monitoring the operating status of a micro lubricator, characterized in that: The micro lubricator comprises a first housing (1), a second housing (2), a first bracket (3), a second bracket (4), a fixing plate (5), a third bracket (6), a first spring (7), a first support plate (8), an oil bag (9), a second support plate (10), a hollow plunger (11), a driving gear set (12), a motor (13), a shift fork (14), a second spring (15), two sets of cams (16) and an oil leakage column (17). The second housing (2) is mounted on the first housing (1), the first bracket (3) and the second bracket (4) are both mounted inside the first housing (1), the fixing plate (5) is mounted on the first housing (1), the first spring (7) is mounted on the first bracket (3), the first spring (7) is mounted inside the second housing (2), the first support plate (8) is mounted on the bottom of the first spring (7), and the oil bag (9) is mounted on the second support plate (10). The bag (9) is mounted on the second bracket (4) through the second support plate (10), and a one-way valve is arranged at the bottom of the oil bag (9). The hollow plunger (11) is slidably mounted on the middle part of the second housing (2), and the oil leakage column (17) is mounted on the bottom of the hollow plunger (11). The driving gear set (12) is mounted on the third bracket (6). The motor (13) is fixedly mounted on the third bracket (6), and the output end of the motor (13) is meshedly connected with the rear part of the driving gear set (12). One end of the shift fork (14) is rotatably mounted on the third bracket (6). The second spring (15) is sleeved on the hollow plunger (11), and the top end of the second spring (15) is clamped on the second bracket (4). The other end of the shift fork (14) is clamped on the hollow plunger (11), and the two sets of cams (16) are both rotatably mounted on the front part of the driving gear set (12). According to the characteristics of the micro lubricator's periodic operation, a standard operation curve is drawn and different current monitoring thresholds are set. The current model of the lubricator during operation is compared with the standard model to infer the type of lubricator failure, including the following steps: S1. The micro lubricator is running. The battery supplies power to the motor (13) at a fixed time according to a predetermined time program. After the motor (13) is powered on, it drives the driving gear set (12) to drive the cam (16) to move. The cam (16) pushes the shift fork (14) in contact with the cam, thereby enabling the shift fork (14) to drive the hollow plunger (11) to move upward. A second spring (15) is pressed on the hollow plunger (11). The second spring (15) is squeezed. When the cam (16) reaches the highest point through a circular motion, it contacts the shift fork (14). 14) is disengaged, and the shift fork (14) drives the hollow plunger (11) to move downward rapidly under the action of the squeezed second spring (15). During the upward movement of the hollow plunger (11), the grease in the upper cavity is squeezed into the oil leakage column (17). During the downward movement of the hollow plunger (11), the grease in the oil leakage column (17) is ejected, and a vacuum is formed in the upper cavity. When the top of the hollow plunger (11) is connected to the oil bag (9), the grease in the oil bag (9) is sucked into the upper cavity, preparing for the next grease discharge; S2, monitoring threshold setting, according to the operating voltage of the motor (13), setting the maximum current of the first two seconds when the driving gear set (12) is idling, and setting the maximum current when the cam (16) pushes the shift fork (14) to compress the second spring (15) to do work; S3, current monitoring: after the program is started, the current of the electronic control unit is monitored according to the threshold value, and different fault codes are used to prompt the staff according to the monitoring results; The current monitoring method comprises the following steps: S3.1, after the program is started, the shift fork (14) is at a certain position, the electronic control unit has current output, and the maximum operating current in the first six seconds is continuously higher than the preset maximum current by more than 1.5 times, at this time it can be considered that the motor (13) is faulty or the drive gear set (12) is stuck, and the corresponding fault code E01 is prompted; S3.2, after the program is started, the shift fork (14) is at a certain position, the electronic control unit has current output, and in the first half of two seconds, it runs at the preset idling current of the drive gear set (12), the running current does not increase significantly, and the maximum running current is less than half of the preset maximum current. In the second half, the current increases, and the maximum current is less than the preset maximum current. At this time, it can be considered that the motor (13) has no fault, and the shift fork (14) starts to be forced from the middle part to push the second spring (15) to compress and do work. At this time, it can be considered that there is a pipeline oil blockage fault, and the corresponding fault code E02 can be prompted; S3.3, after the program is started, the shift fork (14) is at a certain position. Within the first six seconds, the electronic control unit has current output, but the operating current runs at the preset no-load current of the drive gear set (12). At this time, it can be considered that the drive gear set (12) is disconnected from the motor (13), and the motor (13) has an idling fault, prompting the corresponding fault code E03; S3.4, after the program is started, the shift fork (14) is at a certain position. Within the first six seconds, the electronic control unit has no current output. At this time, it is considered that the power line of the motor (13) is disconnected, and the corresponding fault code E04 is prompted; During the current monitoring process, the micro-lubricator is in normal working condition, a complete working cycle does not exceed ten seconds, and it is a periodic operation to prevent the electronic control program from being disordered and continuous. The total running time is added to the program to constrain the program so that the program stops working after the time is reached.

2. A method for monitoring the operation status of a micro lubricator according to claim 1, characterized in that: The driving gear set (12) is a four-stage double gear for speed reduction, and the reduction ratio is 1100. The large reduction ratio is used to reduce the speed of the motor (13) and increase the torque.

3. A method for monitoring the operation status of a micro-lubricator according to claim 1, characterized in that: The micro lubricator is provided with a control panel and an indicator light. The control panel is provided with a display screen. The fault code is displayed on the display screen of the control panel, and the indicator light flashes to remind the staff.

4. A method for monitoring the operation status of a micro-lubricator according to claim 3, characterized in that: The current monitoring process can be operated manually, or the data can be sent to the cloud through wireless communication. The cloud program will make a judgment. When the cloud determines that the data exceeds a set threshold, an alarm will be sent back to the control panel or electronic control board of the micro lubricator.

5. A method for monitoring the operating status of a micro-lubricator according to claim 1, characterized in that: The electronic control program can not only run regularly according to its own timer, but also trigger the operation of the lubricator according to an external timer or other sensors.

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