Intelligent lubricating system for overhead working vehicle and control method of intelligent lubricating system

Abstract

The invention discloses an intelligent lubricating system for an overhead working vehicle and a control method thereof.The intelligent lubricating system comprises a lubricating pump, the lubricating pump communicates with a distributor, a plurality of cavities communicating in sequence are formed in the distributor, and lubricating channel detection sensors are connected to the cavities; the lubrication channel detection sensor is arranged at an oil outlet of one lubrication channel, the lubrication channel detection sensor is connected with an input port of the PLC, when the plunger rod moves to the side wall of the cavity, the lubrication channel detection sensor outputs an in-place detection signal to the PLC, and circulation counting of the lubrication system is started. The method can effectively avoid the problems that timing is inaccurate, the vehicle is excessively lubricated, grease at a lubricating point of the vehicle overflows, grease is wasted and the use of the vehicle is affected due to the fact that the actual running time and the running working condition of the vehicle cannot be effectively judged during automatic time counting and timing of the vehicle lubricating pump; and the situation that vehicle hardware is abraded due to untimely lubrication caused by manual lubrication can be effectively avoided, and meanwhile man-machine interaction is increased.

Description

Technical Field

[0001] The invention relates to an intelligent lubrication system and a control method thereof, and in particular to an intelligent lubrication system for an aerial work vehicle and a control method thereof. Background Art

[0002] At present, large-scale engineering machinery vehicles all use pins to connect various structural parts to achieve the movement of various vehicle components, such as the extension and retraction of active outriggers, the rotation, extension and retraction of booms, etc. There is hard connection friction in the relative movement process between various components and pins. In order to reduce the friction at the connection and movement of moving parts and ensure the good operation of the movement conditions, lubricating oil is usually injected into the connection and movement parts to lubricate the interconnected moving parts, thereby improving the smoothness of vehicle operation and the service life of the vehicle. Usually, the lubrication system is divided into manual lubrication and automatic lubrication.

[0003] The manual lubrication system requires manual injection of grease into the lubrication points to achieve lubrication of the moving parts. The automatic lubrication system generally delivers grease to each lubrication point in sequence through a lubrication pump, which is more convenient than manual lubrication.

[0004] The automatic lubrication system of aerial work vehicles generally adopts manual start and automatic counting. The manual start method is to set a "lubrication" button on the fire control panel, power on the lubrication pump, and start the vehicle lubrication system. Usually, this button is a self-reset button. The lubrication time is controlled according to the length of time the button is pressed. It is highly dependent on human operation. The automatic counting method is that the lubrication pump comes with a simple control panel, which can realize the timing and counting functions; usually the timing starts when the vehicle is powered on, and a certain interval can be set to lubricate several cycles or a certain period of time. This method is simple to control and cannot meet the requirements of starting the lubrication system according to the specific operating conditions of the vehicle. It is easy to cause excessive injection of grease, causing grease to overflow from the lubrication points of the entire vehicle, affecting the safety and aesthetics of the vehicle's use environment, and then causing grease waste.

[0005] If the button is self-locking and is manually opened, there is a risk that the button will be forgotten to be closed and the lubrication system will continue to run, causing the vehicle to be over-lubricated and grease to fall from different parts of the vehicle. At the same time, the long-term operation of the lubrication pump is likely to damage the lubrication pump motor. If the button is self-reset, the operator needs to keep the button pressed, and cannot judge the lubrication condition of the lubrication system on the vehicle's lubrication points. The operator can only press the button for a certain period of time based on experience, which is very blind. At the same time, the button start method cannot intelligently sense the use of grease. When there is no grease, manual judgment is required, which affects the timeliness of vehicle lubrication, untimely lubrication or excessive lubrication.

[0006] The automatic counting method is adopted. The simple control panel of the lubrication pump can only count according to the power-on time of the vehicle, but not according to the vehicle's operating conditions. The actual lubrication needs of the vehicle are unclear. When the interval time is set to be short, it is easy to cause the vehicle to be overlubricated; if the time is set too long, it is easy to cause lack of lubrication. This method starts counting when the vehicle is powered on. There is a situation where the vehicle does not move after the vehicle is powered on, but the lubrication system timing system still counts. Therefore, the vehicle's working condition is not accurately controlled, and accurate lubrication of the vehicle cannot be achieved. At the same time, the remaining grease alarm of this method can only be prompted by the flashing light of the lubrication pump. The human-computer interaction is not strong, and there are phenomena that are not easy to detect. Summary of the invention

[0007] Purpose of the invention: The purpose of the present invention is to provide an intelligent lubrication system and a control method for aerial work vehicles to achieve intelligent and precise lubrication.

[0008] Technical solution: The present invention includes a lubrication pump, which is connected to a distributor. The distributor is provided with a plurality of cavities connected in sequence. A lubrication channel detection sensor is connected to the cavity. The lubrication channel detection sensor is arranged at one of the oil outlets of the lubrication channel. The lubrication channel detection sensor is connected to the input port of the PLC. When the plunger rod moves to the side wall of the cavity, the lubrication channel detection sensor outputs an arrival detection signal to the PLC, and the lubrication system starts to count cycles.

[0009] An oil inlet is provided on one side of the lubrication pump, and the other end of the oil inlet is communicated with the top of the distributor, so as to realize synchronous progressive lubrication of different lubrication points of the vehicle.

[0010] The cavities are all provided with plunger rods, and the upper and lower adjacent cavities are connected vertically through symmetrically distributed middle channels.

[0011] One end of the middle channel corresponds to the lower position connected to the upper cavity, and the position corresponds to the notch of the plunger rod to realize the flow of grease.

[0012] The upper part of the cavity corresponding to the notch of the plunger rod is respectively connected to different oil outlets, and the number of the oil outlets is selected according to the requirements of the lubrication points of the vehicle.

[0013] A liquid level detection sensor is provided in the lubrication pump, and the liquid level detection sensor is connected to the input port of the PLC so as to monitor the usage of the tank lubricating grease in real time.

[0014] A motor is provided at the bottom of the lubrication pump, and a motor control interface is provided on one side of the motor for controlling the start and stop of the lubrication pump motor.

[0015] The motor control interface is connected to the output port of the PLC, and the vehicle-mounted PLC controls the power on and off of the motor control interface to realize the start control of the electric or pneumatic lubrication pump.

[0016] The PLC is connected to a display, which can effectively display the remaining amount of grease in the lubrication system and related information such as the number of lubrication times and lubrication time of the lubrication system. It can provide effective reminders for lubrication system failures and monitor the working status of the lubrication system.

[0017] A control method for an intelligent lubrication system for an aerial work vehicle comprises the following steps:

[0018] S1. When the lubrication button is not pressed, the vehicle enters the automatic intelligent lubrication control mode. When the vehicle starts running, the PLC starts the lubrication timing t1. Here, t1 is the cumulative timing, and it will not be cleared when the vehicle is powered off.

[0019] S2, set the time interval T1 as the interval between two automatic lubrications. When t1>T1, start the automatic lubrication system, the lubrication pump motor runs, start the lubrication pump, and start the lubrication timer t2 at the same time;

[0020] S3, when the lubrication pump delivers grease to the distributor, the lubrication channel detection sensor outputs a signal to the PLC, and the single cycle time is recorded as T2, △T3 is the fault tolerance time for the lubrication channel detection sensor to receive the signal, and t3 is the single duration of the channel position detection signal. When t3>T2 / 2+△T3, if the lubrication channel detection sensor signal is not received, an alarm signal is output, and it is considered that the distributor has a blockage problem;

[0021] S4, let t4 be the duration of a single failure to detect a signal at the channel position, △T4 be the fault tolerance time for the lubrication channel detection sensor to not receive a signal, when t4>T2 / 2+△T4, if a lubrication channel detection sensor signal is received, an alarm signal is output, and it is considered that the distributor has a blockage problem;

[0022] S5. Set the lubrication time of the lubrication system to T5. When t2>T5, turn off the lubrication system and set the timing of t1 and t2 to zero. Among them, T0 is the single cycle time of the lubrication system distributor, V is the amount of grease required for a single lubrication point, and △V is the single oil output of the oil outlet.

[0023] Beneficial effects: The present invention has the following advantages:

[0024] 1) It can effectively avoid the situation that when the vehicle lubrication pump is automatically counting, it cannot effectively judge the actual running time and operating conditions of the vehicle, resulting in inaccurate timing, causing excessive lubrication of the vehicle, causing grease overflow at the vehicle lubrication points, wasting grease, and affecting the use of the vehicle;

[0025] 2) It can effectively avoid the wear of vehicle hardware caused by untimely lubrication caused by manual lubrication;

[0026] 3) The vehicle lubrication system can be activated in a targeted manner according to the actual operating conditions of the vehicle to achieve the effect of intelligent and precise lubrication;

[0027] 4) Add a human-computer interaction system to provide reminders of the vehicle lubrication system liquid level, dispenser operation status and lubrication status. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 is a flow chart of the present invention;

[0030] Figure 3 This is an application scenario diagram of the intelligent lubrication system of the present invention. DETAILED DESCRIPTION

[0031] The present invention will be further described below in conjunction with the accompanying drawings.

[0032] Example 1

[0033] like Figure 1 As shown, the intelligent lubrication system for aerial work vehicles in this embodiment includes a lubrication pump 1, and an oil inlet 8 is provided on one side of the lubrication pump 1. The other end of the oil inlet 8 is connected to the top of the distributor 6. The distributor 6 is a progressive distributor so as to realize synchronous progressive lubrication of different lubrication points of the vehicle. A plurality of cavities 23 connected in sequence are provided in the distributor 6, and a plunger rod 22 is provided in each cavity 23, wherein the upper and lower adjacent cavities 23 are connected up and down through symmetrically distributed middle channels, and one end of the middle channel corresponds to the lower middle position connected to the upper cavity, and the position corresponds to the notch of the plunger rod 22, so as to realize the flow of grease. The upper part of the cavity 23 corresponding to the notch of the plunger rod 22 is respectively connected to different lubricating grease outlets 9, and the number of oil outlets 9 is selected according to the requirements of the vehicle lubrication points. In this embodiment, five cavities 23 are provided, and each cavity 23 is provided with an oil outlet 9 on both sides, for a total of 10 oil outlets, 1 to 10.

[0034] The lubrication channel detection sensor 7 is connected to the cavity 23, and the lubrication channel detection sensor 7 is arranged at one of the lubrication channel oil outlets. The lubrication channel detection sensor 7 is connected to the input port of the PLC 5; the lubrication channel detection sensor 7 uses a pressure switch or a proximity switch to count the number of cycles. When the plunger rod 22 moves to the right and reaches the side wall of the cavity 23, the lubrication channel detection sensor 7 outputs a detection signal to the PLC controller, and the lubrication system cycle count begins. At this time, the oil outlet No. 10 is filled with oil.

[0035] When all the plunger rods 22 are on the left side, the oil outlets are filled with oil in the order of port 10 → port 1 → port 2 → ... → port 9. After all the oil ports are filled with oil, a lubrication oil filling cycle is realized. When the first plunger rod moves to the left to fill port 5 with oil, the lubrication channel detection sensor 7 has no signal output. After entering the second cycle, the lubrication channel detection sensor 7 outputs a signal to the PLC again to complete the second cycle count.

[0036] A liquid level detection sensor 4 is provided in the lubrication pump 1 to detect the usage of the grease. The detection sensor can be a pressure sensor, a position sensor, or a float, a photoelectric liquid level sensor or other sensor that can detect the liquid level. The liquid level detection sensor 4 is connected to the input port of the PLC 5 to monitor the usage of the tank grease in real time.

[0037] A motor 3 is provided at the bottom of the lubrication pump 1, and a motor control interface 2 is provided on one side of the motor 3 for controlling the start and stop of the motor of the lubrication pump 1. The motor control interface 2 is connected to the output port of the PLC 5, and the on-board PLC controls the power on and off of the motor control interface 2 to realize the start control of the electric or pneumatic lubrication pump. The PLC 5 is connected to the display 10, which can effectively display the remaining grease of the lubrication system and the number of lubrications and lubrication time of the lubrication system. It can effectively remind the lubrication system of failures and realize the monitoring of the working status of the lubrication system.

[0038] Figure 3As an example of applying the intelligent lubrication system for aerial work vehicles of this embodiment to a fire truck, the application lubrication points on the fire truck are mainly arranged on some moving hinges or slewing supports of the fire truck. The lubrication pump 1 is generally arranged in front of the turntable, the progressive distributor is generally arranged on the inner side of the turntable, and the motor control interface 2 controls the start and stop of the lubrication pump; the lubrication pump has its own motor 3 to provide power for the lubrication pump to pump oil; a liquid level detection sensor 4 is provided in the lubrication pump 1 to detect the grease level in the lubrication pump tank; the lubrication channel detection sensor 7 is generally integrated with the progressive distributor and arranged at one of the lubrication channel outlets to detect the number of lubrication operation cycles of the lubrication pump, where the lubrication channel detection sensor 7 is set at the oil outlet 1; the oil inlet 8 connects the oil outlet of the lubrication pump 1 and the oil inlet of the distributor 6; the lubrication pipeline 11 of the upper right hinge of the boom is symmetrical with the lubrication pipeline 12 of the upper left hinge of the boom. For the sake of clarity, only the left-side variable-length oil cylinder 20 is shown in the figure here. The actual vehicle model is usually equipped with two left and right variable-length oil cylinders to support the variable-length rise and fall of the entire boom 19, and the hinge points on the variable-length cylinders are respectively connected through the upper right hinge of the boom. The lubrication pipeline 11 and the upper left hinge lubrication pipeline 12 of the boom are used for hinge lubrication. The lubrication pipeline 15 of the lower hinge of the right boom luffing cylinder is symmetrical with the lubrication pipeline 16 of the lower hinge of the left boom luffing cylinder. The lower hinge of the luffing cylinder is lubricated through the lubrication pipeline 15 of the lower hinge of the right boom luffing cylinder and the lubrication pipeline 16 of the lower hinge of the left boom luffing cylinder respectively. The luffing action of some models can also only adopt single-cylinder lifting and lowering, and the lubrication method at the upper and lower hinges is adopted. The lubrication pipeline 13 of the lower right hinge of the boom is symmetrical with the lubrication pipeline 14 of the lower left hinge of the boom. The left and right hinges are connected to the boom 19 and the turntable 18 together, providing a rotating fixed point for the boom 19 to change its length relative to the turntable 18. The hinge is lubricated through the lubrication pipeline 13 of the lower right hinge of the boom and the lubrication pipeline 14 of the lower left hinge of the boom respectively. The slewing bearing lubrication pipeline 17 is used for the lubrication of the slewing support 21 connecting the turntable 18 and the lower vehicle (not shown in the figure here).

[0039] The intelligent lubrication system of this embodiment uses the lubrication channel detection sensor to detect the signal, and combines it with the vehicle operation status to perform the on-board controller logic operation, and sets the lubrication cycle of the corresponding lubrication system according to the vehicle working condition, so as to achieve the purpose of intelligent opening and closing of the vehicle lubrication system. At the same time, the system can read the liquid level detection signal of the grease tank of the lubrication system to monitor the capacity of the lubricating grease. The intelligent lubrication system and its control scheme can effectively solve the problem of grease waste caused by automatic opening of the lubrication pump, affecting the appearance, and the problem of insufficient lubrication when the lubrication is manually opened. By adding a human-computer interaction system, you can enter the corresponding interface to view the last lubrication time and the corresponding lubrication time. At the same time, you can monitor the grease capacity of the lubrication tank for timely filling and maintenance, and issue lubrication system fault reminders, which can effectively capture lubrication system fault information and improve the efficiency of vehicle lubrication system fault diagnosis.

[0040] Example 2

[0041] like Figure 2 As shown, the control method of the intelligent lubrication system for aerial work vehicles of this embodiment includes the following steps:

[0042] S1. When the lubrication button is not pressed, the vehicle enters the automatic intelligent lubrication control mode, collects the lubrication pump power take-off connection state and the engine start state to determine whether the vehicle is moving. When the lubrication pump power take-off is in the connection state and the engine is started, it is considered that the vehicle starts to run. At this time, the on-board PLC starts the lubrication timing t1. Here, t1 is the cumulative timing, which will not be cleared when the vehicle is powered off;

[0043] S2. Set the time interval T1 as the interval between two automatic lubrications through experience and calculation. When t1>T1, start the automatic lubrication system. At this time, the controller outputs a signal through the output port to control the operation of the lubrication pump motor, start the lubrication pump, and start the lubrication timer t2.

[0044] S3. When the lubrication pump continuously delivers grease to the progressive distributor through the oil outlet, the lubrication channel detection sensor outputs a signal to the PLC. The single cycle time is recorded as T2, △T3 is the fault tolerance time for allowing the lubrication channel detection sensor to receive the signal, and t3 is set as the single duration of the channel position detection signal. When t3>T2 / 2+△T3, the lubrication channel detection sensor signal is not received, and an alarm signal is output. It is considered that the distributor has a blockage problem and needs corresponding maintenance.

[0045] S4. Let t4 be the duration of a single failure to detect a signal at the channel position, △T4 be the fault tolerance time that allows the lubrication channel detection sensor to fail to receive a signal. When t4>T2 / 2+△T4, if a lubrication channel detection sensor signal is received, an alarm signal is output, indicating that the distributor has a blockage problem and requires corresponding maintenance.

[0046] S5, set the lubrication time of the lubrication system to T5, then when t2>T5, turn off the lubrication system, turn off the lubrication indicator light, and set t1 and t2 timing to zero. T5 can be calculated by the three variables of the single cycle time T0 of the lubrication system distributor, the required grease volume V of a single lubrication point, and the single oil output volume △V of the oil outlet, using the formula: The calculated T5 can be revised accordingly based on the actual vehicle test conditions.

Claims

1. An intelligent lubrication system for aerial work vehicles, comprising a lubrication pump, the lubrication pump being connected to a distributor, the distributor being provided with a plurality of cavities connected in sequence, characterized in that: A lubrication channel detection sensor is connected to the cavity, and the lubrication channel detection sensor is arranged at one of the lubrication channel oil outlets. The lubrication channel detection sensor is connected to the input port of the PLC. When the plunger rod moves to the side wall of the cavity, the lubrication channel detection sensor outputs an in-place detection signal to the PLC, and the lubrication system cycle count begins.

2. The intelligent lubrication system for aerial work vehicles according to claim 1, characterized in that: An oil inlet is arranged on one side of the lubrication pump, and the other end of the oil inlet is communicated with the top of the distributor.

3. The intelligent lubrication system for aerial work vehicles according to claim 1, characterized in that: The cavities are all provided with plunger rods, and the upper and lower adjacent cavities are connected vertically through symmetrically distributed middle channels.

4. The intelligent lubrication system for aerial work vehicles according to claim 3, characterized in that: One end of the middle channel corresponds to the lower position connected to the upper cavity, and the position corresponds to the notch of the plunger rod.

5. The intelligent lubrication system for aerial work vehicles according to claim 4, characterized in that: The upper part of the cavity corresponding to the notch of the plunger rod is respectively connected to different oil outlets.

6. The intelligent lubrication system for aerial work vehicles according to claim 1, characterized in that: A liquid level detection sensor is arranged in the lubrication pump, and the liquid level detection sensor is connected to the input port of the PLC.

7. The intelligent lubrication system for aerial work vehicles according to claim 1, characterized in that: A motor is arranged at the bottom of the lubrication pump, and a motor control interface is arranged at one side of the motor.

8. The intelligent lubrication system for aerial work vehicles according to claim 7, characterized in that: The motor control interface is connected to the output port of the PLC.

9. The intelligent lubrication system for aerial work vehicles according to claim 1, characterized in that: The PLC is connected to the display.

10. A control method for an intelligent lubrication system for aerial work vehicles according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1. When the lubrication button is not pressed, the vehicle enters the automatic intelligent lubrication control mode. When the vehicle starts running, the PLC starts the lubrication timing t1. Here, t1 is the cumulative timing, and it will not be cleared when the vehicle is powered off. S2, set the time interval T1 as the interval between two automatic lubrications. When t1>T1, start the automatic lubrication system, the lubrication pump motor runs, start the lubrication pump, and start the lubrication timer t2 at the same time; S3, when the lubrication pump delivers grease to the distributor, the lubrication channel detection sensor outputs a signal to the PLC, and the single cycle time is recorded as T2, △T3 is the fault tolerance time for the lubrication channel detection sensor to receive the signal, and t3 is the single duration of the channel position detection signal. When t3>T2 / 2+△T3, if the lubrication channel detection sensor signal is not received, an alarm signal is output, and it is considered that the distributor has a blockage problem; S4, let t4 be the duration of a single failure to detect a signal at the channel position, △T4 be the fault tolerance time for the lubrication channel detection sensor to not receive a signal, when t4>T2 / 2+△T4, if a lubrication channel detection sensor signal is received, an alarm signal is output, and it is considered that the distributor has a blockage problem; S5. Set the lubrication time of the lubrication system to T5. When t2>T5, turn off the lubrication system and set the timing of t1 and t2 to zero. Among them, T0 is the single cycle time of the lubrication system distributor, V is the amount of grease required for a single lubrication point, and △V is the single oil output of the oil outlet.

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