Automatic lubrication control system

Abstract

The invention discloses an automatic lubrication control system, belongs to the technical field of lubrication systems, and aims to monitor a lubrication system of equipment on an industrial site in real time and reduce the failure rate. Comprising a plurality of double-line distributors, a control layer and a platform layer, the plurality of double-line distributors and a plurality of lubricating pumps in a lubricating system of industrial equipment are arranged in a one-to-one correspondence mode, and each double-line distributor is used for distributing a lubricating agent from the corresponding lubricating pump to a corresponding lubricating point and collecting running state data of the double-line distributor; the control layer comprises a programmable control module and Internet of Things gateway equipment, and the programmable control module is used for analyzing and processing the running state data and generating a control instruction when the running state data is analyzed to meet a preset early warning standard; the control layer controls the corresponding double-line distributor and / or the lubricating system to execute corresponding actions according to the control instruction, and the Internet of Things gateway equipment transmits real-time state information and data of the lubricating system to the platform layer and converts the real-time state information and data into business data in the platform layer.

Description

Technical Field

[0001] The invention relates to the technical field of lubrication systems, in particular to an automatic lubrication control system. Background Art

[0002] In the operation of modern industrial equipment, the efficiency and reliability of the lubrication system have an important impact on the overall performance of the equipment. Lubrication not only reduces the friction between mechanical parts, but also extends the service life of the equipment. However, traditional lubrication systems mainly rely on manual inspections, which has a series of limitations:

[0003] First, manual inspections usually cannot achieve real-time monitoring, which can easily lead to failure to detect lubrication failures in time, resulting in serious consequences such as equipment wear and even downtime. Equipment downtime may cause production interruptions, affecting product delivery and production progress. Secondly, the frequency and accuracy of manual inspections are limited by human resources and technical levels, making it difficult to ensure that the lubrication system is always in the best condition. In addition, possible omissions during manual inspections will also increase the company's maintenance costs and downtime.

[0004] The disclosure of the above background technology content is only used to assist in understanding the concept and technical solution of the present invention. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above content has been disclosed on the filing date of this patent application, the above background technology should not be used to evaluate the novelty and creativity of the present application. Summary of the invention

[0005] The present application provides an automatic lubrication control system, which can monitor the lubrication system of equipment on industrial sites in real time and reduce the failure rate.

[0006] To achieve the above-mentioned purpose, the embodiment of the present application discloses the following technical solutions: an automatic lubrication control system, comprising a plurality of two-line distributors and a control layer, wherein the plurality of two-line distributors are arranged in one-to-one correspondence with a plurality of lubrication pumps in the lubrication system of the industrial equipment, and each two-line distributor is used to distribute the lubricant from its corresponding lubrication pump to its corresponding lubrication point, and collect its own operating status data; the control layer comprises a programmable controller module, and the programmable controller module is used to analyze and process the operating status data, and generate a control instruction when it is analyzed that the operating status data meets the preset early warning standard; the control layer controls the corresponding two-line distributor and / or the lubrication system to perform corresponding actions according to the control instruction.

[0007] In an embodiment of the present application, a two-line distributor corresponds one-to-one with the lubrication pump of the industrial equipment, and the lubricant is distributed to the corresponding lubrication points, and its operating status data is collected in real time and transmitted to the control layer. In this way, the data can be analyzed and processed by the programmable controller module of the control layer. When the operating status data is within the preset warning value range (greater than the set value and / or less than the set value), the programmable controller module generates a control instruction, and the control layer performs corresponding operations according to these instructions (such as adjusting lubricant distribution, closing faulty lubrication points, etc.). In this way, real-time monitoring of the lubrication system is achieved, so that abnormal conditions can be discovered in time, and measures can be taken in time to solve them, thereby effectively reducing the failure rate. In addition, the frequency of manual inspections and possible omissions are reduced, which can effectively reduce the maintenance costs of the enterprise. In summary, cost reduction and efficiency improvement can be achieved.

[0008] In some possible implementations, the two-wire distributor is a wireless transmission two-wire type, the operating status data includes the filling pressure data at each oil outlet of the two-wire distributor, the two-wire distributor includes a pressure sensor arranged at each oil outlet, and the two-wire distributor collects the filling pressure data through the pressure sensor; the programmable controller module includes a central processing unit, the central processing unit is used to analyze the filling pressure data, and when the filling pressure data is analyzed to be within the preset warning value range, a control instruction is generated; the control layer controls the corresponding two-wire distributor to perform corresponding actions according to the control instruction. Among them, the two-wire distributor transmits the operating status data wirelessly, which can simplify the system wiring requirements, reduce the complexity of installation and maintenance, and improve the flexibility of system deployment. The real-time monitoring of the filling pressure data by the central processing unit can improve the response speed and maintenance efficiency of the system. Specifically, when it is detected that the pressure of a lubrication point drops abnormally or the pressure is less than the set value, the system can immediately adjust the supply of lubricant or issue a fault warning to prevent the equipment from wearing or failing due to improper lubrication.

[0009] In some possible implementations, the automatic lubrication control system further includes a platform layer, which is used to receive the operating status data sent by the control layer, and the platform layer further includes a data analysis module, which is used to draw a lubrication system working status diagram, a temperature, humidity and flow data curve, and a filling pressure trend diagram according to the filling pressure data. In this way, maintenance personnel can visually observe the pressure changes through the lubrication system working status diagram, the temperature, humidity and flow data curve, and the filling pressure trend diagram, judge the system status, and help predict possible failures in advance and take preventive measures.

[0010] In some possible implementations, the control layer includes an IoT gateway device and a programmable controller, the control layer exchanges data with the platform layer through the IoT gateway device, and executes control instructions sent by the platform layer through the programmable controller. In this way, data processing speed and efficiency are improved and delays are reduced.

[0011] In some possible implementations, the programmable controller is provided with a touch screen, so that the system operation status can be viewed in real time through the touch screen, and an intuitive user interface can also be provided for easy operation and monitoring.

[0012] In some possible implementations, the platform layer is a public cloud or private cloud server. In this way, on the one hand, it can provide elastic computing resources to meet different business needs; on the other hand, it can ensure the security and reliability of data storage.

[0013] In some possible implementations, the operating status data further includes lubricant addition amount data of each lubrication point of the dual-line distributor; the dual-line distributor further includes a plurality of volume sensors, the plurality of volume sensors are arranged corresponding to its own plurality of lubrication points, and each volume sensor is used to collect lubricant addition amount data of its corresponding lubrication point;

[0014] The programmable controller module includes a sensor unit, which is used to analyze the lubricant addition data of each lubrication point. When the lubricant addition data of each lubrication point is greater than the corresponding preset warning value, a control instruction is generated. The control layer controls the two-line distributor to stop supplying lubricant to the corresponding lubrication point according to the control instruction. In this way, it can ensure that the lubricant is supplied on demand and avoid oversupply; in this way, on the one hand, lubricant waste is avoided, thereby reducing costs, and on the other hand, excessive lubricant can be avoided. Increased bearing temperature caused by excessive lubricant. In addition, the use of volumetric metering can make the oil supply accurate and unaffected by system pressure.

[0015] In some possible implementations, the operating status data also includes the movement data of the internal piston of the two-line distributor, and the two-line distributor also includes a Hall sensor and a channel sensor, and the two-line distributor collects the movement data of the internal piston of the two-line distributor through the Hall sensor and the channel sensor. In this way, the movement of the internal piston can be monitored in real time to ensure the normal operation of the two-line distributor and the stable supply of lubricant.

[0016] In some possible implementations, the automatic lubrication control system further includes an application layer, and the platform layer is connected to the application layer for data exchange, and is used to send setting data to the application layer or receive control instructions sent by the application layer, and send them to the control layer to remotely control the two-line distributor and / or the lubrication system to perform corresponding actions. In this way, on the one hand, remote monitoring and control can be achieved, which is convenient for management; on the other hand, it is convenient to notify maintenance personnel to take immediate measures to prevent equipment damage or shutdown.

[0017] In some possible implementations, the application layer includes at least one of the following options: a WeChat applet based on cloud data in a preset terminal device, an installed application software, and a web client. In this way, it is convenient for users to view and control the lubrication system, which can improve the convenience of use. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following briefly introduces the drawings required for the embodiments or the prior art descriptions. It should be understood that in all the drawings, the same reference numerals represent the same elements. In the drawings, for the sake of clarity and ease of understanding, the sizes of some features may be deformed.

[0019] Figure 1 A schematic diagram of the structure of an automatic lubrication control system provided in some embodiments of the present application;

[0020] Figure 2 for Figure 1 The structural schematic diagram of the double-line distributor in the automatic lubrication control system shown;

[0021] Figure 3 for Figure 1 The structural diagram of the control layer in the automatic lubrication control system shown;

[0022] Figure 4 for Figure 3 The schematic diagram of the structure of the programmable controller module in the control layer shown;

[0023] Figure 5 for Figure 1 The structural schematic diagram of the platform layer in the automatic lubrication control system shown;

[0024] Figure 6 for Figure 1 The figure shows a schematic diagram of the user interface of the application layer in the automatic lubrication control system. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] It should be noted that, in the description of the present invention, terms such as "center", "upper", "lower", "horizontal", "inner", etc. indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0027] In addition, it should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0028] See also Figure 1 and Figure 2 An embodiment of the present application provides an automatic lubrication control system, including multiple dual-line distributors 1 and a control layer 2. The multiple dual-line distributors 1 are arranged in one-to-one correspondence with multiple lubrication pumps in the lubrication system of industrial equipment. Each dual-line distributor 1 is used to distribute the lubricant from its corresponding lubrication pump to its corresponding lubrication point and collect its own operating status data; illustratively, the lubricant can be lubricating oil or grease.

[0029] The control layer 2 includes a programmable controller module 21, which is used to analyze and process the operating status data. When the operating status data is analyzed to meet the preset warning standards, a control instruction is generated; the control layer 2 controls the corresponding two-line distributor 1 and / or lubrication system to perform corresponding actions according to the control instruction.

[0030] In this way, the lubricant is distributed to the corresponding lubrication points through the two-line distributor 1 and the lubrication pump of the industrial equipment, and its operating status data is collected in real time and transmitted to the control layer 2. In this way, the data can be analyzed and processed by the programmable controller module 21 of the control layer 2. When the operating status data is within the preset warning value range (greater than the set value and / or less than the set value), the programmable controller module 21 generates a control instruction, and the control layer 2 performs corresponding operations according to these instructions (such as adjusting lubricant distribution, closing faulty lubrication points, etc.). In this way, real-time monitoring of the lubrication system is achieved, so that abnormal conditions can be discovered in time, and measures can be taken in time to solve them, thereby effectively reducing the failure rate. In addition, the frequency of manual inspections and possible omissions are reduced, which can effectively reduce the maintenance costs of the enterprise. In summary, cost reduction and efficiency improvement can be achieved.

[0031] See also Figure 2-Figure 4 In some embodiments, the two-wire distributor 1 is a wireless transmission two-wire type, and the operating status data includes the filling pressure data at each oil outlet of the two-wire distributor 1. The two-wire distributor 1 includes a pressure sensor 11 arranged at each oil outlet, and the two-wire distributor 1 collects the filling pressure data through the pressure sensor 11; the programmable controller module 21 includes a central processing unit 211, and the central processing unit 211 is used to analyze the filling pressure data, and when the filling pressure data is analyzed to be within the preset warning value range, a control instruction is generated; the control layer 2 controls the corresponding two-wire distributor 1 to perform corresponding actions according to the control instruction. Among them, the two-wire distributor 1 transmits the operating status data by wireless means, which can simplify the system wiring requirements, reduce the complexity of installation and maintenance, and improve the flexibility of system deployment. The real-time monitoring of the filling pressure data by the central processing unit 211 can improve the response speed and maintenance efficiency of the system. Specifically, when it is detected that the pressure of a lubrication point drops abnormally or the pressure is less than the set value, the system can immediately adjust the supply of lubricant or issue a fault warning to prevent the equipment from being worn or failing due to improper lubrication.

[0032] See also Figure 5 In some embodiments, the automatic lubrication control system further includes a platform layer 3, which is used to receive the operating status data sent by the control layer 2. The platform layer 3 also includes a data analysis module 31, which is used to draw a lubrication system working status diagram, a temperature, humidity and flow data curve, and a filling pressure trend diagram according to the filling pressure data. In this way, maintenance personnel can visually observe the pressure changes through the lubrication system working status diagram, the temperature, humidity and flow data curve, and the filling pressure trend diagram, judge the system status, and help predict possible failures in advance and take preventive measures.

[0033] In some embodiments, the platform layer 3 is a public cloud or a private cloud server. In this way, on the one hand, it can provide elastic computing resources to meet different business needs; on the other hand, it can ensure the security and reliability of data storage.

[0034] See also Figure 3 In some embodiments, the control layer 2 includes an IoT gateway device 23 and a programmable controller 22. The control layer 2 exchanges data with the platform layer 3 through the IoT gateway device 23, and executes the control instructions sent by the platform layer 3 through the programmable controller 22. In this way, the data processing speed and efficiency are improved and the delay is reduced.

[0035] In some embodiments, the programmable controller 22 is equipped with a touch screen. In this way, the system operation status can be viewed in real time through the touch screen. In addition, an intuitive user interface can be provided for easy operation and monitoring. Specifically, the touch screen can be used to display all current alarms and historical fault records, and to perform remote communication, upload control layer 2 data to platform layer 3, and receive platform layer 3 cloud data and control instructions.

[0036] See also Figure 2 and Figure 4 In some embodiments, the operating status data further includes lubricant addition amount data of each lubrication point of the dual-line distributor 1; the dual-line distributor 1 further includes a plurality of volume sensors 12, the plurality of volume sensors 12 are arranged corresponding to its own plurality of lubrication points, and each volume sensor 12 is used to collect lubricant addition amount data of its corresponding lubrication point;

[0037] The programmable controller module 21 includes a sensor unit 212, which is used to analyze the lubricant addition data of each lubrication point. When the lubricant addition data of each lubrication point is greater than the corresponding preset warning value, a control instruction is generated, and the control layer 2 controls the two-line distributor 1 to stop supplying lubricant to the corresponding lubrication point according to the control instruction. In this way, it can ensure that the lubricant is supplied on demand and avoid oversupply; in this way, on the one hand, lubricant waste is avoided, thereby reducing costs, and on the other hand, excessive lubricant can be avoided. Increased bearing temperature caused by excessive lubricant. In addition, the use of volumetric metering can make the oil supply accurate and unaffected by system pressure.

[0038] In some embodiments, the operation status data also includes the action data of the internal piston of the two-line distributor 1. The two-line distributor 1 also includes a Hall sensor 13 and a channel sensor 14. The two-line distributor 1 collects the action data of the internal piston of the two-line distributor 1 through the Hall sensor 13 and the channel sensor 14. In this way, the action of the internal piston can be monitored in real time to ensure the normal operation of the two-line distributor 1 and the stable supply of lubricant.

[0039] It is understandable that the above embodiment only schematically introduces some components of the two-wire distributor 1, and it cannot be understood that the two-wire distributor 1 only includes these components. For example, the two-wire distributor 1 also includes a controller, a wireless communication module and a battery.

[0040] See also Figure 1 and Figure 6In some embodiments, the automatic lubrication control system further includes an application layer 4, and the platform layer 3 is connected to the application layer 4 for data exchange, and is used to send setting data to the application layer 4 or receive control instructions sent by the application layer 4, and send them to the control layer 2 to remotely control the two-line distributor 1 and / or the lubrication system to perform corresponding actions. In this way, on the one hand, remote monitoring and control can be achieved, which is convenient for management; on the other hand, it is convenient to notify maintenance personnel to take immediate measures to prevent equipment damage or shutdown.

[0041] Exemplarily, system information can be transmitted to the cloud, server or smartphone client via a 4G / 5G SIM card with activated data transmission, and up to 256 contacts (including but not limited to maintenance personnel) can be configured for SMS service.

[0042] Of course, the present application is not limited to this. In other embodiments, the application layer 4 can also be used to freely configure device indicators, configure after-sales processes, freely define BI and reports, support secondary development through interfaces through open API libraries, support data access from other systems; support customized development and deep algorithm analysis based on data and artificial intelligence; 4) support overseas device access and multi-language and world map applications.

[0043] In some embodiments, the application layer 4 includes at least one of the following options: a WeChat applet based on cloud data in a preset terminal device, an installed application software, and a web client. In this way, it is convenient for users to view and control the lubrication system, which can improve the convenience of use.

[0044] Of course, the present application is not limited thereto. In other embodiments, the operating status data may also include information such as the temperature, angle, signal value, communication status, signal strength, battery power, temperature and humidity of the two-wire distributor 1 itself.

[0045] Specifically, through the cooperation of the control layer 2 and the platform layer 3, the oil level in the oil storage tank can be monitored, and the replenishing oil pump can be automatically controlled according to the oil level, such as a shutdown alarm when the oil level is too low and an overflow alarm when the oil level is too high; the running status of the lubrication pump is monitored, and various protections such as overload, short circuit, and overcurrent are provided; the oil supply status of the system is monitored, and an automatic alarm is issued if the oil supply exceeds the set time; the outlet pressure of the lubrication pump is monitored, and an automatic shutdown alarm is issued if the lubrication pump exceeds the set pressure; the action status of the reversing valve and the inlet and outlet pressures are automatically detected, and the system can be automatically shut down if a valve fails; the refueling amount and refueling cycle are determined according to the characteristics of the equipment bearings and the speed requirements, and refueling is automatically scheduled and quantitative; the temperature, humidity, acceleration, power, and flow signals of the lubrication system are cyclically self-checked, fault alarms are output for abnormal points, and faults are locked and eliminated in time.

[0046] The control layer 2 can also realize manual control. The platform layer 3 can realize detailed recording of the oil supply data of all oil supply points according to the data reported by the two-line distributor 1; and classify and record the fault information of the distributor. In addition, it can also support remote debugging and downloading of devices in the SGLAN network, such as programmable controller 22, touch screen with communication function, etc.

[0047] It is understandable that the automatic lubrication control system is applicable to most industrial environments. For example, the applicable scenarios in steel enterprises include:

[0048] 1) High temperature, multiple points, continuous production areas, such as steelmaking overhead crane, continuous casting area, etc.

[0049] 2) Equipment with high automation and high speed, such as hot rolling press, coil box, laminar roller, transport roller, working roller, etc., cold rolling furnace roller, twenty-roller, six-stand, finishing unit, etc. 3) Areas with large areas, many points, and areas that require manual inspection, such as ironmaking belts.

[0050] With the support of this automatic lubrication control system, the benefits achieved on site include:

[0051] 1) Intelligent control can realize automatic inspection, status monitoring, trend analysis, fault alarm, etc., reduce the workload of workers on site, reduce unnecessary downtime, and reduce the number of people close to the running equipment, eliminating safety hazards.

[0052] 2) Accurately control the amount of oil added, reduce grease consumption, and reduce environmental and fire hazards caused by excess grease accumulation, while achieving the goal of cost savings.

[0053] The present invention and its embodiments are described above, and such description is not restrictive. What is shown in the full text is only one of the embodiments of the present invention, and the actual structure is not limited thereto. In short, if ordinary technicians in the field are inspired by it, without departing from the purpose of the invention, they can design a structure and embodiment similar to the technical solution without creativity, which should belong to the protection scope of the present invention.

Claims

1. An automatic lubrication control system, characterized in that: include: A plurality of two-line distributors, each of which is arranged in one-to-one correspondence with a plurality of lubrication pumps in a lubrication system of an industrial device, and each of which is used to distribute lubricant from its corresponding lubrication pump to its corresponding lubrication point and collect its own operating status data; The control layer includes a programmable controller module, and the programmable controller module is used to analyze and process the operating status data. When it is analyzed that the operating status data meets the preset early warning standard, a control instruction is generated; the control layer controls the corresponding two-line distributor and / or lubrication system to perform corresponding actions according to the control instruction.

2. The automatic lubrication control system according to claim 1, characterized in that: The two-wire distributor is of wireless transmission two-wire type, the operating status data includes filling pressure data at each oil outlet of the two-wire distributor, the two-wire distributor includes a pressure sensor arranged at each oil outlet, and the two-wire distributor collects the filling pressure data through the pressure sensor; The programmable controller module includes a central processing unit, which is used to analyze the filling pressure data and generate a control instruction when it is analyzed that the filling pressure data is within a preset warning value range; the control layer controls the corresponding two-line distributor to perform corresponding actions according to the control instruction.

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

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

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

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

7. The automatic lubrication control system according to any one of claims 2 to 6, characterized in that: The operating status data also includes lubricant addition amount data of each lubrication point of the dual-line distributor; the dual-line distributor also includes a plurality of volume sensors, the plurality of volume sensors are arranged corresponding to the plurality of lubrication points thereof, and each of the volume sensors is used to collect the lubricant addition amount data of the corresponding lubrication point; The programmable controller module includes a sensor unit, which is used to analyze the lubricant addition data of each lubrication point. When it is analyzed that the lubricant addition data of each lubrication point is greater than its corresponding preset warning value, a control instruction is generated. The control layer controls the two-line distributor to stop supplying lubricant to the corresponding lubrication point according to the control instruction.

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

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

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

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