Equipment state monitoring and intelligent lubricating system based on few-point dispersed scene

Abstract

The invention relates to an equipment state monitoring and intelligent lubricating system based on a few-point dispersed scene. The system mainly comprises a lubrication module, display hardware, an equipment management platform and a data acquisition module, the data acquisition module comprises a vibration sensor, a temperature sensor, a rotating speed sensor and a data acquisition unit, and the data acquisition module transmits data to the equipment management platform through a wireless communication module. Or data is transmitted to the lubrication controller through the wireless communication module and / or in a wired mode; according to vibration, temperature and rotating speed numerical values fed back by the three sensors, through analysis of the data processing module, the client terminal can check the running state and the lubricating state of the equipment in real time through the terminal, and according to changes of the running state of the equipment, self-adaptive adjustment or remote manual adjustment of the lubricating strategy of the lubricating system through the terminal is achieved. And the fault conditions of equipment and a lubricating system can be known in time, the automation degree is remarkably improved, and the manual labor intensity and the maintenance cost are greatly reduced.

Description

Technical Field

[0001] The present invention relates to a device status monitoring and intelligent lubrication system based on a scenario with few and scattered points. Background Art

[0002] In the field of dry oil automatic lubrication of equipment, some equipment has fewer and more scattered parts that need to be filled with grease (abbreviated as lubrication points), such as the cement industry, the wind power industry, and small production lines. The lubrication points on the equipment are few and scattered, and the distance between multiple equipment is also relatively far. The traditional centralized lubrication system cannot meet the requirements and mainly has the following problems: 1. The centralized lubrication system is installed on the equipment, and its working status cannot be known. Even when the maintenance personnel arrive at the equipment, at most they can see whether the centralized lubrication system is working, but the effectiveness of the lubrication system's work cannot be known, that is, it cannot be known whether the amount of grease filled in the friction pairs of the equipment is appropriate, and good lubrication of the equipment cannot be ensured. The maintenance personnel still need to frequently check the equipment status; 2. The traditional centralized lubrication system is based on the lubrication strategy set by the program according to the lubrication requirements of each friction pair of the equipment during installation, such as filling 1 ml of grease into lubrication point No. 1 and 3 ml of grease into lubrication point No. 2 every hour... However, when the working status of the equipment changes, the traditional centralized lubrication system cannot sense the change in the working status of the equipment, so it cannot adapt to adjust the lubrication strategy, and the maintenance personnel cannot know the change in the working status of the equipment in time, and the maintenance personnel cannot manually adjust the lubrication strategy of the centralized lubrication system either, which will also lead to poor lubrication of the equipment; 3. Since the lubrication points of the equipment are relatively scattered, the corresponding lubrication systems are also relatively scattered. In order to check the status of the lubrication system in time and replenish the required grease in time, the maintenance personnel need to arrive at each scattered lubrication system in turn during each maintenance, and the workload is very large, which also causes many users to abandon the lubrication system and adopt traditional manual lubrication. Summary of the Invention

[0003] Based on the above problems, the present invention provides a device status monitoring and intelligent lubrication system based on a scenario with few and scattered points. This system can view the operating status and lubrication status of the equipment in real time through the terminal, adaptively adjust or remotely manually adjust the lubrication strategy of the lubrication system through the terminal according to the change in the operating status of the equipment, and can timely know the equipment failure situation and the abnormal situation of the lubrication system, so as to timely go to the fault point to check the fault, timely go to the lubrication system reporting the abnormality to check the status of the lubrication system and replenish the grease, etc. The degree of automation is significantly improved, and the manual labor intensity and maintenance cost are greatly reduced.

[0004] The technical solution of the present invention is as follows: A device status monitoring and intelligent lubrication system based on a scenario with few and scattered points includes: Lubrication module, used to pump lubricating grease to each lubrication point after pressurization, including a centralized lubrication system and / or single-point grease injectors installed on each dispersedly arranged device. The centralized lubrication system includes a distributor and is used for installation on devices with multiple lubrication points and relatively concentrated lubrication points. The single-point grease injector is used for installation on a device with only one lubrication point or on a device with multiple lubrication points and relatively dispersed lubrication points; the lubrication system and the single-point grease injector are provided with a lubrication controller, and the lubrication controller includes a wireless communication module and an oil level detection module; Data acquisition module, including a vibration sensor, a temperature sensor, a rotation speed sensor, and a data collector for collecting signals of the three sensors. The three sensors are respectively used for collecting the vibration, temperature, and rotation speed values of the device; Customer terminal, including display hardware and a device management platform. The device management platform includes a wireless communication module and a data processing module. The lubrication controller exchanges data with the device management platform through the wireless communication module; The data acquisition module transmits data to the device management platform through the wireless communication module, or transmits data to the lubrication controller through the wireless communication module and / or wired connection; During operation, based on the vibration, temperature, and rotation speed values feedback by the three sensors, the customer terminal can obtain the lubrication state and the device operation state through analysis by the data processing module, including the device fault type and corresponding position information, the lubrication system abnormal type and corresponding position information, and then perform fault alarm, or form a new lubrication strategy instruction and send it to the lubrication controller to control the lubrication module to execute the corresponding lubrication strategy.

[0005] Furthermore, it includes a grease replenishment module. The grease replenishment module includes a lubricating grease storage barrel, an electric grease replenishment pump, and a tubing joint assembly. The electric grease replenishment pump includes a grease replenishment controller, and the grease replenishment controller is controlled and connected to the lubrication controller. When the oil level detection module of the lubrication controller detects that the oil level reaches the lowest set value, the device management platform sends a grease replenishment instruction to the lubrication controller, and the lubrication controller sends a grease replenishment start instruction to the grease replenishment controller to control the operation of the electric grease replenishment pump to pump the lubricating grease in the lubricating grease storage barrel to the fuel tank of the lubrication module under pressure. When the oil level detection module detects that the oil level reaches the highest set value, the device management platform sends a stop grease replenishment instruction to the lubrication controller, and the lubrication controller sends a grease replenishment stop instruction to the grease replenishment controller to control the electric grease replenishment pump to stop running.

[0006] Furthermore, a distributor action state detection module is provided on the distributor of the centralized lubrication system and is controlled and connected to the corresponding lubrication controller for detecting and feeding back the working state of the distributor.

[0007] Furthermore, the wired connection method between the data acquisition module and the lubrication controller is a 485 bus or a can bus or an Ethernet cable.

[0008] Further, the vibration sensor is a uniaxial vibration acceleration sensor.

[0009] Further, the vibration sensor and the temperature sensor adopt a temperature-vibration integrated sensor.

[0010] Further, the rotational speed sensor is a Hall rotational speed sensor.

[0011] Further, the data transmitted by the lubrication controller to the equipment management platform includes the starting time of grease supply, the grease supply amount, the pressure of the lubricating grease, the number of plunger movements of the dispenser and the running time, and the liquid level alarm information when the liquid level of the lubricating grease reaches the set maximum and minimum values.

[0012] Further, the centralized lubrication system is a single-line centralized lubrication system or a double-line centralized lubrication system or a progressive centralized lubrication system.

[0013] Advantages of the present invention: An equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points of the present invention is mainly applicable to scenarios where there are many and scattered equipment in the cement industry, wind power industry, small production lines, etc., and there are few and scattered lubrication points on each equipment. Since the lubrication module and the data acquisition module can transmit the starting time of grease supply, the grease supply amount, the pressure of the lubricating grease, the number of plunger movements of the dispenser and the running time, the liquid level alarm information when the liquid level of the lubricating grease reaches the set maximum and minimum values, the vibration data, temperature data, and rotational speed data of the equipment, etc. to the equipment management platform of the client, users can view the operating status and lubrication status of the equipment in real time through a mobile terminal, and can timely know the equipment failure situation and the abnormal situation of the lubrication system, so as to promptly go to the fault point to check for faults, promptly go to the lubrication system with reported abnormalities to check the lubrication system status and replenish lubricating grease, etc. Since the equipment management platform can analyze various signals collected through data comparison with the database, calculate the type of the operating status of the equipment, transmit data to the lubrication controller through the equipment management platform, adaptively adjust or remotely manually adjust the lubrication strategy of the lubrication system through the terminal, the automation degree is significantly improved, and the manual labor intensity and maintenance cost are greatly reduced. Description of the Drawings

[0014] Figure 1 It is a schematic diagram of the system principle of Embodiment 1 of an equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points of the present invention; Figure 2 It is a schematic diagram of the system principle of Embodiment 2 of an equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points of the present invention; Figure 3 It is a system architecture diagram corresponding to the equipment management platform; In the figure: 1 - Lubrication module, 11 - Lubrication pump, 111 - Distributor, 12 - Single-point greasing device, 2 - Data acquisition module, 21 - Vibration sensor, 22 - Temperature sensor, 23 - Rotation speed sensor, 3 - Customer terminal, 31 - Display hardware, 32 - Equipment management platform, 4 - Grease replenishment module, 41 - Grease storage barrel, 42 - Electric grease replenishment pump. Detailed implementation manners

[0015] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention, that is, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Usually, the components of the embodiments of the present invention described and shown in the accompanying drawings herein can be arranged and designed in various different configurations.

[0016] Therefore, the detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed present invention, but only represents the selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative efforts belong to the scope of protection of the present invention.

[0017] It should be noted that relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprise", "include" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising a..." does not exclude the existence of additional identical elements in the process, method, article or device including the said element.

[0018] The features and performance of the present invention will be further described in detail below with reference to the embodiments.

[0019] Embodiment 1 of an equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points of the present invention: As Figure 1 shown, an equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points includes a lubrication module 1, a grease replenishment module 4, a data acquisition module 2, and a customer terminal 3.

[0020] Among them, the lubrication module 1 is used to pump the grease to each lubrication point after pressurization, including a centralized lubrication system and single-point grease injectors 12 installed on each separately arranged device. The specific structures of the centralized lubrication system and the single-point grease injectors 12 are prior arts and will not be elaborated in detail. It is only necessary to know that the centralized lubrication system generally includes a lubrication pump 11, a distributor 111, a wiring harness connector, etc. Among them, the lubrication pump 11 includes an oil tank and a pump head. A lubrication controller is provided on the pump head to control the operation of the lubrication pump 11 and monitor the system oil pressure, temperature, and the working state of the distributor 111. The oil tank stores grease. The pump head has a power part that can extract the grease in the oil tank and pressurize it to send it to the distributor 111. The distributor 111 can quantitatively distribute the grease to different lubrication points. In this embodiment, the centralized lubrication system is suitable for lubricating several to dozens of relatively concentrated lubrication points and is installed on or near the installation equipment. In this embodiment, the single-point grease injector 12 mainly includes a pump head, an oil tank, and a lubrication controller. Its main function is the same as that of the lubrication pump 11, but it has only one grease outlet, which is directly connected to the lubrication point and is not equipped with a distributor 111 for grease quantity distribution. It is mainly suitable for being installed on a device with only one lubrication point or a device with multiple lubrication points and relatively scattered lubrication points. Lubrication controllers are provided on the lubrication system and the single-point grease injectors 12. The lubrication controller includes a wireless communication module and an oil level detection module. A distributor 111 action state detection module is provided on the distributor 111 of the centralized lubrication system, such as a Hall sensor used to detect the plunger action of the distributor 111, and is controlled and connected to the corresponding lubrication controller for detecting and feeding back the working state of the distributor 111. The centralized lubrication system can be a single-line centralized lubrication system, a double-line centralized lubrication system, or a progressive centralized lubrication system.

[0021] The grease replenishment module 4 includes a grease storage barrel 41, an electric grease replenishment pump 42, and a tubing joint assembly. The electric grease replenishment pump 42 includes a replenishment controller, and the replenishment controller is controlled and connected to the lubrication controller. When the oil level detection module of the lubrication controller detects that the oil level reaches the lowest set value, the equipment management platform sends a grease replenishment instruction to the lubrication controller, and the lubrication controller sends a grease replenishment start instruction to the replenishment controller to control the operation of the electric grease replenishment pump 42 to pressurize and pump the grease in the grease storage barrel 41 into the oil tank of the lubrication module. When the oil level detection module detects that the oil level reaches the highest set value, the equipment management platform sends a stop grease replenishment instruction to the lubrication controller, and the lubrication controller sends a grease replenishment stop instruction to the replenishment controller to control the electric grease replenishment pump 42 to stop operating.

[0022] The data acquisition module 2 includes a vibration sensor 21, a temperature sensor 22, a speed sensor 23, and a data collector for collecting signals of the three sensors. The three sensors are used to collect vibration, temperature, and speed values ​​of the equipment, respectively, and are fixedly installed at appropriate positions of the equipment to be lubricated, and mainly detect the vibration, temperature, and speed data at the lubrication points of the lubricated parts. The vibration sensor 21 is a uniaxial vibration acceleration sensor, or the vibration sensor 21 and the temperature sensor 22 use a temperature-vibration integrated sensor, and the speed sensor 23 is a Hall speed sensor 23.

[0023] In this embodiment, the data collector sets one channel for vibration, temperature and speed respectively, and reserves 4G\RS485\RJ45 communication interface. The vibration sensor 21 is a single-axis vibration acceleration with analog output. The temperature sensor 22 is a PT100 or a transmitter output analog quantity.

[0024] The client terminal 3 includes display hardware 31 and device management platform 32. Display hardware 31 can be various intelligent terminals such as mobile phones, tablet computers, laptops, desktop computers, vehicle-mounted computers, instrument monitors, etc. The device management platform 32 is a software platform that runs on the corresponding intelligent terminal in the form of web pages and APPs. The device management platform 32 includes a wireless communication module and a data processing module. The lubrication controller exchanges data with the device management platform 32 through the wireless communication module. The system architecture corresponding to the device management platform 32 is as follows: Figure 3 The equipment management platform 32 uses a big data platform and an analysis and diagnosis algorithm to determine whether each lubrication point needs oiling and lubrication, and can issue lubrication instructions to the corresponding lubrication system according to the selection, thereby realizing intelligent lubrication of each lubrication point.

[0025] In this embodiment, Figure 1 As shown, the data acquisition module 2 transmits data to the device management platform 32 via the wireless communication module; in Example 2, as Figure 2 As shown, the data acquisition module 2 transmits data to the lubrication controller via a wired method. The wired connection between the data acquisition module 2 and the lubrication controller is a 485 bus or a CAN bus or an Ethernet cable. In other embodiments, the data acquisition module 2 and the lubrication controller may also transmit data via a wireless communication module.

[0026] During operation, based on the vibration, temperature, and rotational speed values feedback by three types of sensors, the customer terminal 3 can, through analysis by the data processing module, obtain the lubrication state and the equipment operation state, including the equipment fault type and the corresponding location information, the lubrication system abnormal type and the corresponding location information, and then conduct fault alarms or form new lubrication strategy instructions to be sent to the lubrication controller to control the lubrication module 1 to execute the corresponding lubrication strategy. A device status monitoring and intelligent lubrication system based on a scenario with few and scattered points of the present invention is mainly applicable to scenarios where there are many and scattered devices in industries such as the cement industry, the wind power industry, and small production lines, and there are few and scattered lubrication points on each device. Since the lubrication module 1 and the data acquisition module 2 can transmit in real time the grease supply start time, the grease supply amount, the pressure of the lubricating grease, the number of plunger movements and the operation time of the distributor 111, the liquid level alarm information when the liquid level of the lubricating grease reaches the set maximum and minimum values, the vibration data, the temperature data, and the rotational speed data of the equipment, etc. to the device management platform 32 of the client, so the user can view the operation state and the lubrication state of the device in real time through the mobile terminal, and can timely know the device fault situation and the abnormal situation of the lubrication system, so as to timely go to the fault point to check for faults, timely go to the lubrication system with reported abnormalities to check the lubrication system state and replenish lubricating grease, etc. Since the device management platform 32 can, through data comparison and analysis with the database of the various signals collected, calculate the type of the operation state of the device, transmit data to the lubrication controller via the device management platform 32, adaptively adjust or remotely manually adjust the lubrication strategy of the lubrication system through the terminal, the degree of automation is significantly improved, and the manual labor intensity and the maintenance cost are greatly reduced.

[0027] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. The patent protection scope of the present invention is subject to the claims. Any equivalent structural changes made by using the description and drawings of the present invention shall, by the same token, be included in the protection scope of the present invention.

Claims

1. An equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points, characterized in that, Including: A lubrication module for pumping lubricating grease to each lubrication point after pressurization, including a centralized lubrication system and / or single-point grease injectors installed on each of the dispersed equipment. The centralized lubrication system includes a distributor and is used for installation on equipment with multiple lubrication points and relatively concentrated lubrication points. The single-point grease injector is used for installation on equipment with only one lubrication point or on equipment with multiple lubrication points and relatively dispersed lubrication points. A lubrication controller is provided on the lubrication system and the single-point grease injector. The lubrication controller includes a wireless communication module and an oil level detection module; A data acquisition module, including a vibration sensor, a temperature sensor, a speed sensor, and a data collector for collecting signals from the three sensors. The three sensors are respectively used for collecting the vibration, temperature, and speed values of the equipment; A customer terminal, including a display hardware and a device management platform. The device management platform includes a wireless communication module and a data processing module. The lubrication controller exchanges data with the device management platform through the wireless communication module; The data acquisition module transmits data to the device management platform through the wireless communication module, or transmits data to the lubrication controller through the wireless communication module and / or a wired manner; During operation, based on the vibration, temperature, and speed values fed back by the three sensors, the customer terminal can, through analysis by the data processing module, obtain the lubrication state and the equipment operation state, including the equipment fault type and the corresponding position information, and the lubrication system abnormal type and the corresponding position information, and then perform a fault alarm, or form a new lubrication strategy instruction and send it to the lubrication controller to control the lubrication module to execute the corresponding lubrication strategy.

2. The device status monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, wherein, A distributor action state detection module is provided on the distributor of the centralized lubrication system and is controlled and connected to the corresponding lubrication controller for detecting and feeding back the working state of the distributor.

3. An equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, characterized in that, Including a grease replenishment module. The grease replenishment module includes a lubricating grease storage barrel, an electric grease replenishment pump, and a tubing joint assembly. The electric grease replenishment pump includes a grease replenishment controller, and the grease replenishment controller is controlled and connected to the lubrication controller. When the oil level detection module of the lubrication controller detects that the oil level reaches the lowest set value, the device management platform sends a grease replenishment instruction to the lubrication controller, and the lubrication controller sends a grease replenishment start instruction to the grease replenishment controller to control the operation of the electric grease replenishment pump to pump the lubricating grease in the lubricating grease storage barrel to the fuel tank of the lubrication module under pressure. When the oil level detection module detects that the oil level reaches the highest set value, the device management platform sends a stop grease replenishment instruction to the lubrication controller, and the lubrication controller sends a grease replenishment stop instruction to the grease replenishment controller to control the electric grease replenishment pump to stop running.

4. The device status monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, characterized in that, The wired connection method between the data acquisition module and the lubrication controller is a 485 bus or a can bus or an Ethernet cable.

5. The device status monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, wherein The vibration sensor is a single-axis vibration acceleration sensor.

6. The device state monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, characterized in that, The vibration sensor and the temperature sensor adopt a temperature-vibration integrated sensor.

7. An equipment status monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, characterized in that, The speed sensor is a Hall speed sensor.

8. The device status monitoring and intelligent lubrication system based on the scenario of few and scattered points according to claim 1, wherein, The data transmitted by the lubrication controller to the device management platform includes the grease supply start time, the grease supply amount, the pressure of the lubricating grease, the number of plunger movements and the running time of the distributor, and the liquid level alarm information when the liquid level of the lubricating grease reaches the set maximum and minimum values.

9. The device status monitoring and intelligent lubrication system based on a scenario with few and scattered points according to claim 1, characterized in that, The centralized lubrication system is a single-line centralized lubrication system, a double-line centralized lubrication system, or a progressive centralized lubrication system.

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