Intelligent grease injection method and system based on sensor

Abstract

The invention discloses an intelligent grease injection method and system based on a sensor. The method comprises the steps that equipment start / stop signals, the rotating speed of a rotating shaft, bearing temperature operation parameters and the like are collected through the sensor; starting / stopping the grease injector in a linkage manner when judging that the starting / stopping state of the equipment is changed; accumulated consumption of lubricating grease is calculated according to existing parameters, and the grease injection amount is dynamically adjusted; and the bearing operation state is diagnosed according to the existing parameters, and when the control system judges that the equipment bearing is in the abnormal operation state, early warning / alarm processing is started. Automatic lubrication and grease injection can be achieved when electromechanical equipment is unattended, the labor cost is reduced, lubricating grease is saved, and the equipment reliability is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of fat injection, and in particular to a sensor-based intelligent fat injection method and system. Background Art

[0002] Large and medium-sized electromechanical equipment is one of the most important assets in modern industrial production. Various bearing components are used in these electromechanical equipment, and most of these bearing components are lubricated with grease. The main functions of grease include lubrication, cooling, corrosion prevention, rust prevention, shock absorption, buffering, sealing and protection of bearing surfaces, which can effectively reduce operating friction losses, ensure the normal operation of bearings and extend the service life of equipment.

[0003] During the operation of electromechanical equipment bearings, good lubrication must be ensured. During the operation of bearings, a certain amount of grease will be consumed due to liquefaction, gasification, carbonization and leakage. Moreover, after long-term use, the grease will age and its performance will decline. In addition, factors such as temperature, moisture, dust, and impurities during operation will affect the service life and performance of the grease. Therefore, it is extremely important for electromechanical equipment to regularly replace or update bearing grease.

[0004] There are two methods to replace and update grease: one is to regularly disassemble the equipment and bearings and replace all the grease. This method requires downtime, and the replacement is time-consuming and costly, so it is not suitable for frequent use. Another method is to design a grease injection port on the bearing seat to replenish and update the grease by regular quantitative grease injection. In this method, too little grease injection will lead to poor lubrication, shorten the bearing life, or even damage the bearing. Too much grease injection will lead to serious grease waste and environmental pollution. In addition, too much grease will increase bearing loss and cause the bearing temperature to rise.

[0005] Traditional electromechanical equipment is regularly and quantitatively greased manually, and the grease injection interval and amount are mostly based on experience, with high labor costs, great influence of human factors, and low reliability. With the development of science and technology, automated grease injection equipment has begun to emerge and be applied and promoted, but most of these automated grease injection equipment are limited to adjusting the single grease amount or grease interval according to the bearing model and parameters, and there will be more or less disadvantages of under-lubrication or over-lubrication. Summary of the invention

[0006] In response to the technical problems mentioned above, the purpose of the embodiments of the present application is to propose a sensor-based intelligent grease injection method and system, which realizes the start / stop linkage function, dynamic adjustment function of grease injection amount and bearing status diagnosis function through real-time operating parameters collected by sensors installed on electromechanical equipment, thereby ensuring the minimum grease injection amount while ensuring good bearing lubrication.

[0007] The technical solution of the present invention is as follows.

[0008] On the one hand, a sensor-based intelligent fat injection method includes:

[0009] Acquire real-time operating parameters of electromechanical equipment collected by sensors installed on the electromechanical equipment;

[0010] Obtaining optional functions, wherein the optional functions include one or more of a start / stop linkage function, a grease injection amount dynamic adjustment function, and a bearing status diagnosis function;

[0011] If the start / stop linkage function is selected, the start / stop status of the electromechanical equipment is determined according to the operating parameters of the electromechanical equipment; based on the start / stop status of the electromechanical equipment, the grease injector is started / stopped in linkage;

[0012] If the dynamic adjustment function of grease injection amount is selected, the cumulative consumption of grease for one or more bearings will be calculated according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and the grease injection amount and / or grease injection cycle of the corresponding greaser will be dynamically adjusted;

[0013] If the bearing status diagnosis function is selected, the operating status of the bearing is judged according to the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if the bearing is judged to be operating in the warning state, the warning treatment is initiated; if the bearing is judged to be operating in the alarm state, the alarm treatment is initiated.

[0014] Preferably, the start / stop linkage function is implemented on the corresponding grease injector, and the dynamic adjustment function of the grease injection amount and the bearing status diagnosis function are implemented on the grease injection server.

[0015] Preferably, the start / stop linkage function, the dynamic adjustment function of the grease injection amount and the bearing status diagnosis function are all implemented on the grease injector.

[0016] Preferably, the sensors installed on the electromechanical equipment include one or more of a switch auxiliary contact opening and closing signal DI, a rotation speed sensor AI and a temperature sensor AI.

[0017] Preferably, the operating parameters for determining the start / stop state of the electromechanical equipment include one or more of the start / stop signal, shaft speed, motor current / voltage and diesel engine throttle position; the operating parameters for calculating the cumulative consumption of bearing grease and dynamically adjusting the grease amount and / or grease injection cycle of the corresponding greaser include one or more of the continuous operation time, spindle speed, bearing temperature / temperature rise and start / stop times; the operating parameters for diagnosing bearing operation faults include one or more of the continuous operation time, spindle speed, bearing temperature / temperature rise, bearing seat vibration and bearing operation noise.

[0018] Preferably, dynamically adjusting the injection amount and / or injection cycle of the corresponding grease injector according to the cumulative consumption of the bearing grease specifically includes:

[0019] According to the cumulative consumption of bearing grease, the single injection amount of grease and / or the grease injection interval of the corresponding grease injector are dynamically adjusted.

[0020] Preferably, if it is determined according to the bearing operating status fault diagnosis method that the bearing is in an under-lubricated state, the corresponding grease injection mechanism is controlled to increase the grease injection amount, shorten the grease injection interval, or immediately replenish the grease; if it is determined according to the bearing operating status fault diagnosis method that the bearing is in an over-lubricated state, the corresponding grease injection mechanism is controlled to reduce the grease injection amount or extend the grease injection interval.

[0021] Preferably, the method of initiating early warning processing or initiating alarm processing includes:

[0022] Send one or more of the following: alarm information message, sound and light alarm, pop-up alarm window, screen highlighting alarm information, short message alarm, mobile phone APP alarm, WeChat applet alarm, alarm email and linkage shutdown.

[0023] On the other hand, a sensor-based intelligent grease injection system includes a sensor, a grease injector, and a grease injection server;

[0024] The sensor is installed on the electromechanical equipment and is used to collect the real-time operating parameters of the corresponding electromechanical equipment;

[0025] The grease injector comprises a first parameter acquisition module and a start / stop linkage module;

[0026] The first parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0027] The start / stop linkage module is used to determine the start / stop state of the electromechanical equipment according to the operating parameters of the electromechanical equipment; based on the start / stop state of the electromechanical equipment, the grease injector is started / stopped in linkage;

[0028] The grease injection server comprises a second parameter acquisition module, a grease injection amount dynamic adjustment module and a bearing state diagnosis module;

[0029] The second parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0030] A dynamic grease injection amount adjustment module is used to calculate the cumulative grease consumption of one or more bearings according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and dynamically adjust the grease injection amount and / or grease injection cycle of the corresponding greaser;

[0031] The bearing status diagnosis module is used to determine the operating status of the bearing based on the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is determined that the bearing is operating in a warning state, the warning treatment is initiated; if it is determined that the bearing is operating in an alarm state, the alarm treatment is initiated.

[0032] In another aspect, a sensor-based intelligent grease injection system includes a sensor, a grease injector, and a grease injection server;

[0033] The sensor is installed on the electromechanical equipment and is used to collect the real-time operating parameters of the corresponding electromechanical equipment;

[0034] The grease injector comprises a first parameter acquisition module, a start / stop linkage module, a grease injection amount dynamic adjustment module and a bearing state diagnosis module;

[0035] The first parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0036] The start / stop linkage module is used to determine the start / stop state of the electromechanical equipment according to the operating parameters of the electromechanical equipment; based on the start / stop state of the electromechanical equipment, the grease injector is started / stopped in linkage;

[0037] A dynamic grease injection amount adjustment module is used to calculate the cumulative grease consumption of one or more bearings according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and dynamically adjust the grease injection amount and / or grease injection cycle of the corresponding greaser;

[0038] The bearing status diagnosis module is used to determine the operating status of the bearing according to the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is determined that the bearing is operating in a warning state, the warning status information is sent to the grease injection server; if it is determined that the bearing is operating in an alarm state, the alarm status information is sent to the grease injection server;

[0039] The grease injection server comprises a second parameter acquisition module, an early warning / alarm handling module and a configuration data sending module;

[0040] The second parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0041] The early warning / alarm handling module receives the early warning / alarm status information sent by the grease injector and starts the early warning / alarm handling;

[0042] The configuration data sending module is used to obtain the technical parameters and configuration parameters of the bearing, and send the technical parameters and configuration parameters of the bearing to the grease injector.

[0043] Compared with the prior art, the present invention has the following beneficial effects:

[0044] (1) The present invention can automatically, dynamically and intelligently inject grease according to the operating conditions of the equipment to ensure that the bearings are well lubricated, while saving labor costs and grease usage, achieving the green goal of low carbon and environmental protection; it has an intelligent diagnosis function for the bearing status, timely discovers the lubrication hazards of the bearings and attempts to intelligently repair the defects. When the operating status of the bearing is seriously abnormal, it promptly alarms and notifies the maintenance personnel to take measures as soon as possible, thereby improving the reliability of the equipment;

[0045] (2) When the grease injection amount dynamic adjustment module and the bearing status diagnosis module of the present invention are deployed on the grease injection server, the control is mainly implemented by the server side, the cost of the grease injector is lower, and it is conducive to large-scale deployment and centralized monitoring;

[0046] (3) When the start / stop linkage module, grease injection amount dynamic adjustment module and bearing status diagnosis module of the present invention are deployed on the greaser, intelligent grease injection can be realized without the server, which is beneficial to the scenarios with wide geographical distribution or harsh on-site environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0048] Figure 1 This is a schematic diagram of the process of the sensor-based intelligent grease injection method according to the first embodiment of the present invention;

[0049] Figure 2 This is a workflow diagram of a sensor-based intelligent grease injection method according to Embodiment 1 of the present invention;

[0050] Figure 3 This is an application block diagram of a sensor-based intelligent grease injection system according to Embodiment 2 of the present invention;

[0051] Figure 4 This is an application block diagram of the sensor-based intelligent grease injection system of embodiment 3 of the present invention. DETAILED DESCRIPTION

[0052] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments, and all other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making creative work are within the scope of protection of the present invention.

[0053] In the description of the present invention, it should be noted that the terms "comprises", "includes" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprises a ..." does not exclude the existence of other identical elements in the process, method, article or device including the element.

[0054] In the description of the present invention, it should be noted that, unless otherwise clearly stipulated and limited, the terms "provided with", "sleeved / connected", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection. It can be a mechanical connection or an electrical connection. It can be a direct connection or an indirect connection through an intermediate medium. It can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0055] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, step identifiers S101, S102, S103, etc. are only used for convenient expression and do not represent the execution order. The corresponding execution order can be adjusted as needed.

[0056] Embodiment 1

[0057] See also Figure 1 and Figure 2 As shown, the present invention discloses a sensor-based intelligent grease injection method, which includes the following steps.

[0058] S101, obtaining real-time operating parameters of the electromechanical equipment collected by sensors installed on the electromechanical equipment.

[0059] Specifically, the sensor installed on the electromechanical equipment of the present invention includes one or more of the switch auxiliary contact opening and closing signal DI, the speed sensor AI and the temperature sensor AI. In addition, the existing digital instrument / device / system can also be used to directly read the operating parameters through the communication interface.

[0060] Specifically, the collected operating parameters include but are not limited to one or more of "start / stop signal, shaft speed, bearing temperature / temperature rise". For equipment with conditions, parameters that can measure the bearing load, such as drive motor current / power, can be used to assist in the accurate calculation of the cumulative consumption of grease, and parameters such as bearing seat vibration and bearing operating noise can be used for accurate diagnosis of bearing faults.

[0061] S102, obtaining optional functions, wherein the optional functions include one or more of a start / stop linkage function, a grease injection amount dynamic adjustment function, and a bearing status diagnosis function.

[0062] Specifically, one or more functions of "start / stop linkage, dynamic adjustment of grease injection amount, bearing status diagnosis, etc." can be selected according to equipment characteristics, site conditions, available operating parameters and customer needs.

[0063] The optional functions may be implemented through the client of the grease injection server, or may be written into the grease injection server and / or grease injector according to actual applications, which is not limited in this embodiment.

[0064] S103, if the start / stop linkage function is selected, the start / stop state of the electromechanical equipment is determined according to the operating parameters of the electromechanical equipment; based on the start / stop state of the electromechanical equipment, the grease injector is started / stopped in linkage.

[0065] In this embodiment, since the operating parameters of the corresponding electromechanical equipment are collected by sensors, the start / stop linkage function is deployed on the grease injector to achieve better control.

[0066] Specifically, the start / stop state of the electromechanical equipment can be directly determined based on the start / stop signal; the start / stop state of the electromechanical equipment can also be determined based on the shaft speed being non-zero / zero; the start / stop state of the equipment can also be determined based on other parameters, such as motor current / voltage, diesel engine throttle position, etc.

[0067] It should be noted that when collecting parameters such as the main machine shaft speed, it is not necessary to collect the start / stop signal, and the start / stop signal can be replaced by a non-zero / zero parameter; similarly, when the equipment speed variation range is small, the start / stop signal can be directly converted to replace the speed parameter. The speed is the rated speed when in the start state and zero when in the stop state. In addition, the linkage start / stop grease injector function can be selected according to the characteristics of the electromechanical equipment, site conditions, available parameters and customer needs.

[0068] S104, if the function of dynamic adjustment of grease injection amount is selected, the cumulative consumption of grease for one or more bearings is calculated according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and the grease injection amount and / or grease injection cycle of the corresponding greaser is dynamically adjusted.

[0069] In this embodiment, the function of dynamically adjusting the amount of grease injected may be deployed on a grease injector or a grease injection server, and is specifically deployed according to application requirements.

[0070] Specifically, the real-time operating parameters used to calculate the cumulative consumption of grease include, but are not limited to, one or more of "operating time, spindle speed, bearing temperature / temperature rise, and number of starts and stops".

[0071] In addition, based on the calculation results of the cumulative grease consumption, both the single grease injection amount and the grease injection interval can be adjusted.

[0072] Since different electromechanical equipment may collect different operating parameters, the dynamic adjustment schemes of the grease injection amount of the corresponding configurations may also be different.

[0073] In this embodiment, the ball bearing of the motor is regularly greased, the grease injection interval is fixed, and the single grease injection amount is dynamically adjusted. The single grease injection amount calculation and dynamic adjustment method are as follows.

[0074] (1) Calculate the standard amount of fat injection G N .

[0075] G N =0.005×D×B

[0076] Wherein, D is the outer diameter of the bearing, in mm; B is the width of the bearing, in mm.

[0077] (2) Calculate the standard grease injection cycle T N .

[0078]

[0079] Among them, K is the influencing factor. The calculation method is different for different types of motors, so the detailed calculation method is omitted; n N is the rated speed, in rpm; d is the bearing inner diameter, in mm.

[0080] T N At the same time, it is sent down as the default parameters for offline greasing and saved in the grease injector.

[0081] (3) Calculate the dynamic grease injection interval T.

[0082]

[0083] Among them, ∑T0 is the cumulative downtime; n t is the real-time speed, in rpm; n t When it reaches zero, the integration stops and the downtime accumulation starts. t When it is non-zero, the integral starts and stops accumulating downtime.

[0084] (4) Actual single fat injection amount G.

[0085] The standard grease injection amount, standard grease injection cycle and dynamic grease injection interval calculated above are all nominal values, not the actual single grease injection amount and actual grease injection interval of the greaser. The greaser actually adopts the strategy of small amount and multiple injections, dividing the nominal single grease injection amount into multiple injections, and the actual grease injection interval T0 is set by the engineer according to the needs of the site.

[0086] G=G N ×T0÷T.

[0087] S105, if the bearing status diagnosis function is selected, the operating status of the bearing is judged according to the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is judged that the bearing is running in the warning state, the warning treatment is started; if it is judged that the bearing is running in the alarm state, the alarm treatment is started.

[0088] In this embodiment, the bearing status diagnosis function can be deployed on a grease injector or a grease injection server, and is deployed specifically according to application requirements.

[0089] Specifically, the operating parameters used to diagnose bearing operating faults include one or more of continuous operating time, spindle speed, bearing temperature / temperature rise, bearing seat vibration and bearing operating noise.

[0090] The bearing operating status fault diagnosis method includes but is not limited to one or more combinations of "threshold determination method, mathematical model determination method and artificial intelligence determination method".

[0091] In the warning state, if the bearing is judged to be under-lubricated according to the expert library rules, the grease injection amount is increased, the grease injection interval is shortened, or the grease is replenished immediately; if the bearing is judged to be over-lubricated according to the expert library rules, the grease injection amount is reduced or the grease injection interval is extended.

[0092] Methods for initiating early warning or alarm handling include:

[0093] One or more of uploading alarm information message, sound and light alarm, pop-up alarm window, screen highlighting alarm information, SMS alarm, mobile phone APP alarm, WeChat applet alarm, sending alarm email and linkage shutdown.

[0094] It should be noted that if the bearing status diagnosis function is deployed on the grease injector, the warning status or alarm status information needs to be sent to the grease injection server, and a warning / alarm is issued through the grease injection server, or sent to the maintenance personnel's email / mobile phone, etc.

[0095] It should be noted that due to customer budget constraints, in order to reduce the operating load of the server, combined with the importance of the equipment and the range of parameters that can be collected, the bearing operating status diagnosis function is only enabled for core equipment and some important equipment, and the diagnosis plans can also be different.

[0096] In summary, the sensor-based intelligent grease injection method of the present invention can automatically, dynamically and intelligently inject grease according to the operating conditions of the equipment to ensure that the bearings are well lubricated, while saving labor costs and grease usage, and achieving the green goal of low carbon and environmental protection; and the present invention has an intelligent diagnosis function for the bearing status, which can promptly discover the lubrication risks of the bearings and attempt to intelligently repair the defects. When the bearing operating status is seriously abnormal, it will promptly alarm and notify the maintenance personnel to take measures as soon as possible to improve the reliability of the equipment.

[0097] Embodiment 2

[0098] Corresponding to the sensor-based intelligent grease injection method of the first embodiment, this embodiment provides a sensor-based intelligent grease injection system, including a sensor, a grease injector and a grease injection server;

[0099] The sensor is installed on the electromechanical equipment and is used to collect the real-time operating parameters of the corresponding electromechanical equipment;

[0100] The grease injector comprises a first parameter acquisition module and a start / stop linkage module;

[0101] The first parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0102] The start / stop linkage module is used to determine the start / stop state of the electromechanical equipment according to the operating parameters of the electromechanical equipment; based on the start / stop state of the electromechanical equipment, the grease injector is started / stopped in linkage;

[0103] The grease injection server comprises a second parameter acquisition module, a grease injection amount dynamic adjustment module and a bearing state diagnosis module;

[0104] The second parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0105] A dynamic grease injection amount adjustment module is used to calculate the cumulative grease consumption of one or more bearings according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and dynamically adjust the grease injection amount and / or grease injection cycle of the corresponding greaser;

[0106] The bearing status diagnosis module is used to determine the operating status of the bearing based on the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is determined that the bearing is operating in a warning state, the warning treatment is initiated; if it is determined that the bearing is operating in an alarm state, the alarm treatment is initiated.

[0107] See also Figure 3The following is a specific application of this embodiment 1. The grease injection server software of this application adopts a C / S+B / S hybrid mode, and the functions of resident workbench, system configuration, equipment management, log query, historical data query, data analysis and mining, report generation, etc. are implemented on the C / S side; historical data query, report download, data analysis form download can also be accessed through B / S in the intranet.

[0108] This embodiment adopts a one-to-many mode, that is, an intelligent grease injection server controls multiple intelligent greasers through a dedicated WiFi network, which can realize intelligent grease injection of multiple sets of major electromechanical equipment in the factory. The dynamic adjustment module of the grease injection amount and the bearing status diagnosis module are mainly implemented on the grease injection server, and the start / stop linkage module is implemented on the intelligent greaser. The intelligent greaser has an offline operation function. When it loses connection with the server, it will automatically switch to the offline operation mode and operate according to the preset grease injection parameters calculated by the system based on the bearing technical parameters.

[0109] It should be noted that different electromechanical equipment is equipped with different data collection sensors. Ordinary electromechanical equipment only collects start / stop signals, enables the start / stop linkage function, and the fixed speed equipment enables the automatic adjustment of grease injection amount function; important equipment collects shaft speed and bearing temperature parameters, enables the start / stop linkage function, the automatic adjustment of grease injection amount function and the state bearing diagnosis function; core equipment also collects bearing seat vibration parameters to achieve more accurate fault diagnosis.

[0110] In addition, for electromechanical equipment with a start / stop signal, the grease injection machine is started / stopped in conjunction with the start / stop signal; in addition, the grease injection machine is started / stopped in conjunction with a speed parameter that is non-zero / zero.

[0111] Specifically, the intelligent grease injection server and the grease injector are connected using communication methods such as RS232 / 485, LAN, WiFi, ZigBee, LoRa, 4G / 5G-LTE, and NB-IoT.

[0112] Embodiment 3

[0113] Corresponding to the sensor-based intelligent grease injection method of the first embodiment, this embodiment provides a sensor-based intelligent grease injection system, including a sensor, a grease injector and a grease injection server;

[0114] The sensor is installed on the electromechanical equipment and is used to collect the real-time operating parameters of the corresponding electromechanical equipment;

[0115] The grease injector comprises a first parameter acquisition module, a start / stop linkage module, a grease injection amount dynamic adjustment module and a bearing state diagnosis module;

[0116] The first parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor;

[0117] The start / stop linkage module is used to determine the start / stop state of the electromechanical equipment according to the operating parameters of the electromechanical equipment; based on the start / stop state of the electromechanical equipment, the grease injector is started / stopped in linkage;

[0118] A dynamic grease injection amount adjustment module is used to calculate the cumulative grease consumption of one or more bearings according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and dynamically adjust the grease injection amount and / or grease injection cycle of the corresponding greaser;

[0119] The bearing status diagnosis module is used to determine the operating status of the bearing according to the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is determined that the bearing is operating in a warning state, the warning status information is sent to the grease injection server; if it is determined that the bearing is operating in an alarm state, the alarm status information is sent to the grease injection server;

[0120] The grease injection server comprises a second parameter acquisition module, an early warning / alarm handling module and a configuration data sending module;

[0121] The second parameter acquisition module is used to obtain the real-time operating parameters of the electromechanical equipment collected by the sensor to perform data query and analysis, table generation and query, etc.;

[0122] The early warning / alarm handling module receives the early warning / alarm status information sent by the grease injector and starts the early warning / alarm handling;

[0123] The configuration data sending module is used to obtain the technical parameters and configuration parameters of the bearing, and send the technical parameters and configuration parameters of the bearing to the grease injector.

[0124] See also Figure 4 The following is a specific application of the first embodiment of the present invention. This application adopts a one-to-many mode, that is, an intelligent grease injection server controls dozens of intelligent greasers through a dedicated WiFi network that is built in conjunction with the server, and can realize the intelligent grease injection of dozens of major electromechanical equipment in the factory. The intelligent grease injection server is only used for parameter configuration, data collection, query and advanced analysis, report generation and query, alarm information push and other functions. The core control modules of the system (start / stop linkage module, grease injection amount dynamic adjustment module and bearing status diagnosis module) are mainly implemented on each greaser. The intelligent greaser has the function of offline operation, and offline operation does not affect its function.

[0125] The biggest difference between the third embodiment and the second embodiment is that the control module of the second embodiment is mainly concentrated on the server side of the grease injection server, which has a lower cost and is conducive to mass deployment and centralized monitoring. The control module of this embodiment is mainly distributed on the intelligent grease injection device, which can be separated from the intelligent grease injection server to realize intelligent grease injection, which is conducive to scenarios such as wide geographical distribution or harsh on-site environment.

[0126] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the spirit and scope of the technical solution of the present invention.

Claims

1. A sensor-based intelligent fat injection method, characterized in that: include: Acquire real-time operating parameters of electromechanical equipment collected by sensors installed on the electromechanical equipment; Obtaining optional functions, wherein the optional functions include one or more of a start / stop linkage function, a grease injection amount dynamic adjustment function, and a bearing status diagnosis function; If the start / stop linkage function is selected, the start / stop status of the electromechanical equipment is determined according to the operating parameters of the electromechanical equipment; Based on the start / stop status of the electromechanical equipment, the grease injector is started / stopped in linkage; If the dynamic adjustment function of grease injection amount is selected, the cumulative consumption of grease for one or more bearings will be calculated according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and the grease injection amount and / or grease injection cycle of the corresponding greaser will be dynamically adjusted; If the bearing status diagnosis function is selected, the operating status of the bearing is judged according to the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if the bearing is judged to be operating in the warning state, the warning treatment is initiated; if the bearing is judged to be operating in the alarm state, the alarm treatment is initiated.

2. The sensor-based intelligent grease injection method according to claim 1, characterized in that: The start / stop linkage function is implemented on the corresponding grease injector, and the dynamic adjustment function of the grease injection amount and the bearing status diagnosis function are implemented on the grease injection server.

3. The sensor-based intelligent grease injection method according to claim 1, characterized in that: The start / stop linkage function, the dynamic adjustment function of the grease injection amount and the bearing status diagnosis function are all realized on the grease injector.

4. The sensor-based intelligent grease injection method according to claim 1, characterized in that: The sensors installed on the electromechanical equipment include one or more of the switch auxiliary contact opening and closing signal DI, the speed sensor AI and the temperature sensor AI.

5. The sensor-based intelligent grease injection method according to claim 1, characterized in that: The operating parameters for determining the start / stop state of the electromechanical equipment include one or more of the start / stop signal, shaft speed, motor current / voltage and diesel engine throttle position; The operating parameters for calculating the cumulative consumption of bearing grease and dynamically adjusting the grease amount and / or grease injection cycle of the corresponding greaser include one or more of the continuous operating time, spindle speed, bearing temperature / temperature rise and number of starts and stops; the operating parameters for diagnosing bearing operating faults include one or more of the continuous operating time, spindle speed, bearing temperature / temperature rise, bearing seat vibration and bearing operating noise.

6. The sensor-based intelligent grease injection method according to claim 1, characterized in that: According to the cumulative consumption of bearing grease, dynamically adjust the injection amount and / or injection cycle of the corresponding greaser, including: According to the cumulative consumption of bearing grease, the single injection amount of grease and / or the grease injection interval of the corresponding grease injector are dynamically adjusted.

7. The sensor-based intelligent grease injection method according to claim 1, characterized in that: If the bearing is judged to be in an under-lubricated state according to the bearing operating status fault diagnosis method, the corresponding grease injection mechanism is controlled to increase the grease injection amount, shorten the grease injection interval, or immediately replenish the grease; if the bearing is judged to be in an over-lubricated state according to the bearing operating status fault diagnosis method, the corresponding grease injection mechanism is controlled to reduce the grease injection amount or extend the grease injection interval.

8. The sensor-based intelligent grease injection method according to claim 1, characterized in that: Methods for initiating early warning or alarm handling include: Send one or more of the following: alarm information message, sound and light alarm, pop-up alarm window, screen highlighting alarm information, short message alarm, mobile phone APP alarm, WeChat applet alarm, alarm email and linkage shutdown.

9. A sensor-based intelligent fat injection system, characterized in that: Including sensors, grease injectors and grease injection servers; The sensor is installed on the electromechanical equipment and is used to collect the real-time operating parameters of the corresponding electromechanical equipment; The grease injector comprises a first parameter acquisition module and a start / stop linkage module; The first parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor; The start / stop linkage module is used to determine the start / stop state of the electromechanical equipment according to the operating parameters of the electromechanical equipment; Based on the start / stop status of the electromechanical equipment, the grease injector is started / stopped in linkage; The grease injection server comprises a second parameter acquisition module, a grease injection amount dynamic adjustment module and a bearing state diagnosis module; The second parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor; A dynamic grease injection amount adjustment module is used to calculate the cumulative grease consumption of one or more bearings according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and dynamically adjust the grease injection amount and / or grease injection cycle of the corresponding greaser; The bearing status diagnosis module is used to determine the operating status of the bearing based on the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is determined that the bearing is operating in a warning state, the warning treatment is initiated; if it is determined that the bearing is operating in an alarm state, the alarm treatment is initiated.

10. A sensor-based intelligent fat injection system, characterized in that: Including sensors, grease injectors and grease injection servers; The sensor is installed on the electromechanical equipment and is used to collect the real-time operating parameters of the corresponding electromechanical equipment; The grease injector comprises a first parameter acquisition module, a start / stop linkage module, a grease injection amount dynamic adjustment module and a bearing state diagnosis module; The first parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor; The start / stop linkage module is used to determine the start / stop state of the electromechanical equipment according to the operating parameters of the electromechanical equipment; Based on the start / stop status of the electromechanical equipment, the grease injector is started / stopped in linkage; A dynamic grease injection amount adjustment module is used to calculate the cumulative grease consumption of one or more bearings according to the operating parameters of the electromechanical equipment, the technical parameters of the bearings and the configuration parameters, and dynamically adjust the grease injection amount and / or grease injection cycle of the corresponding greaser; The bearing status diagnosis module is used to determine the operating status of the bearing according to the operating parameters of the electromechanical equipment, the technical parameters of the bearing and the configuration parameters; if it is determined that the bearing is operating in a warning state, the warning status information is sent to the grease injection server; if it is determined that the bearing is operating in an alarm state, the alarm status information is sent to the grease injection server; The grease injection server comprises a second parameter acquisition module, an early warning / alarm handling module and a configuration data sending module; The second parameter acquisition module is used to acquire the real-time operating parameters of the electromechanical equipment collected by the sensor; The early warning / alarm handling module receives the early warning / alarm status information sent by the grease injector and starts the early warning / alarm handling; The configuration data sending module is used to obtain the technical parameters and configuration parameters of the bearing, and send the technical parameters and configuration parameters of the bearing to the grease injector.

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