Equipment health management system based on lubrication

Abstract

The invention relates to an equipment health management system based on lubrication. The system comprises an automatic grease changing module, a detection module and a client terminal, the automatic grease changing module comprises a centralized lubricating module and a waste grease discharging module, the detection module comprises a lubricating grease quality detection sensor, a temperature sensor and a vibration sensor, and the client terminal mainly comprises display hardware and an equipment management platform. According to vibration, temperature and lubricating grease quality numerical values fed back by the three sensors, the client terminal can obtain lubricating grease state and equipment operation state data including equipment fault types, corresponding position information and lubricating grease deterioration degree through analysis of the data processing module, and then fault alarm is carried out. Or a new grease changing strategy instruction is formed and sent to the lubricating controller and the grease pumping controller, so that the lubricating pump and the grease pumping pump are controlled to execute corresponding grease changing strategies; an automatic grease changing strategy can be changed according to the working state change of the equipment and the quality change of the lubricating grease, so that reasonable and intelligent lubrication of the equipment is realized.

Description

Technical Field

[0001] The present invention relates to a lubrication-based equipment health management system. Background Art

[0002] With the development of intelligence, in the field of centralized grease lubrication, traditional lubrication methods have gradually been unable to meet the increasing needs of customers. Customers hope that their equipment can operate stably and healthily. However, traditional automatic centralized lubrication systems only rely on set programs to inject lubricating grease regularly, quantitatively, and at fixed points. They have no knowledge of changes in the operating state of the equipment, changes in the environment, changes in the quality of the lubricating grease inside the equipment, or even the lubrication conditions of the friction pairs of the equipment, and cannot achieve precise management of the equipment's health status. Therefore, there are situations such as poor lubrication, excessive lubrication, inability to replace deteriorated oil in a timely manner, and although the lubrication system is operating, the set amount of lubricating grease is not injected into the lubrication points. Summary of the Invention

[0003] The purpose of the present invention is to provide a lubrication-based equipment health management system, which can monitor the operating state of the equipment and adjust the lubrication strategy in a timely manner according to changes in the operating state, and can change the automatic grease replacement strategy according to changes in the quality of the lubricating grease, so as to achieve reasonable and intelligent lubrication of the equipment and reduce the probability of equipment failures caused by lubrication problems.

[0004] The technical solution of the present invention is as follows: A lubrication-based equipment health management system includes: An automatic grease replacement module, including a centralized lubrication module for injecting new lubricating grease into the equipment and a waste grease discharge module for sucking out the waste grease in the equipment. The centralized lubrication module includes a lubrication pump and a distributor. The lubrication pump includes a lubrication controller. The waste grease discharge module includes a fat extraction pump and a waste grease collection bucket. The fat extraction pump includes a fat extraction controller; A detection module, including a lubricating grease quality detection sensor for detecting the quality of the used lubricating grease in the friction pairs of the equipment, and a temperature sensor and a vibration sensor for detecting the temperature and vibration conditions of the equipment. Data acquisition modules are respectively provided on the lubricating grease quality detection sensor, the temperature sensor, and the vibration sensor. The lubricating grease quality detection sensor transmits data to the lubrication controller; A customer terminal, including display hardware and an equipment management platform. The equipment management platform includes a wireless communication module and a data processing module. The lubrication controller and the fat extraction controller interact with the equipment management platform through the wireless communication module; The temperature sensor and the vibration sensor transmit data to the equipment management platform through the wireless communication module of the control gateway; During operation, based on the vibration, temperature, and grease quality values fed back by the above three sensors, the customer terminal can analyze through the data processing module to obtain data on the grease state and equipment operation state, including the equipment failure type and corresponding location information, and the degree of grease deterioration. Then, it can perform fault alarms or form new grease replacement strategy instructions and send them to the lubrication controller and fat extraction controller to control the lubrication pump and fat extraction pump to execute the corresponding grease replacement strategy.

[0005] Furthermore, the outlet of the dispenser is connected to each lubrication point through a lubrication pipeline. At one end of the lubrication pipeline close to the lubrication point, there is an end detection sensor for detecting whether the grease is flowing. The end detection sensor transmits data to the lubrication controller. By setting the end detection sensor, the main problem to be solved is that although the existing centralized lubrication system is operating, due to reasons such as poor grease fluidity, long pipelines, and blockages at lubrication points, the grease may not actually be filled to the lubrication points as set, resulting in misjudgment by maintenance personnel. The harm is far greater than not installing a centralized lubrication system. By installing an end detection sensor on the oil pipe close to the lubrication point, it is like installing "eyes" at the lubrication point, enabling maintenance personnel to accurately know the actual grease filling situation at the lubrication point and meeting the requirements of effective lubrication.

[0006] Furthermore, the end detection sensor includes a throttling structure formed by the transition from a large-volume chamber to a small-volume chamber and a pressure sensor arranged in the large-volume chamber for detecting the grease pressure in the large-volume chamber. When the data detected by the pressure sensor reaches the set pressure, it means that the grease supply reaches the lubrication point.

[0007] Furthermore, the data transmitted by the lubrication controller to the equipment management platform includes the start-stop time of the lubrication pump operation, the grease supply volume, the grease pressure in the main pipeline, the data of each end detection sensor, and the data of the grease quality detection sensor. The feedback of the grease pressure data in the main pipeline can determine whether there are faults in the centralized lubrication module itself, such as whether the pipeline is blocked.

[0008] Furthermore, the lubrication pump includes an oil tank, and an oil level detection sensor for detecting the grease level inside it is provided on the oil tank. The setting of the oil level detection sensor enables maintenance personnel to timely know whether there is a lack of grease in the oil tank of the lubrication pump, so as to replenish the grease in time when there is a lack of grease.

[0009] Furthermore, the oil level detection sensor is a laser opposed sensor. The oil level detection sensor transmits data to the lubrication controller and finally feeds it back to the equipment management platform.

[0010] Further, it includes a grease replenishment module. The grease replenishment module includes a grease storage barrel and an electric grease replenishment pump. The electric grease replenishment pump includes a grease replenishment controller. The grease replenishment controller transmits and receives data with the equipment management platform through a wireless communication module. When the oil level detection module of the lubrication controller detects that the oil level reaches the lowest set value, the equipment management platform transmits a grease replenishment instruction to the grease replenishment controller to control the operation of the electric grease replenishment pump, so as to pressurize and pump the grease in the grease storage barrel into the fuel tank of the lubrication pump. When the oil level detection module detects that the oil level reaches the highest set value, the equipment management platform transmits a stop grease replenishment instruction to the grease replenishment controller to control the electric grease replenishment pump to stop operating. After setting the grease replenishment module, the centralized lubrication system can work for a longer time without manual grease replenishment, thereby reducing the maintenance frequency and saving labor costs.

[0011] Further, the liposuction pump is an electric suction and fat removal device.

[0012] Further, the liposuction pump includes a hydraulic power pump and a liquid-controlled suction and fat removal device.

[0013] Further, a plunger action detection module for detecting whether the plunger of the dispenser moves is installed on the dispenser. The setting of the plunger action detection module can mainly know the operating state of the dispenser in time, so as to know and display the fault location in time when the dispenser fails, so that maintenance personnel can eliminate the fault early.

[0014] Further, the plunger action detection module includes a Hall sensor and a permanent magnet part installed on the plunger and used in cooperation with the Hall sensor.

[0015] Further, the grease quality detection sensor includes a humidity detection module for detecting the moisture content in the grease, an iron filings detection module for detecting the iron filings content in the grease, and a temperature detection module for detecting the temperature of the grease.

[0016] Further, the wireless communication module includes LORA or zigbee or 4G.

[0017] Further, the vibration sensor and the temperature sensor adopt a temperature-vibration integrated sensor.

[0018] Further, the centralized lubrication module is a single-line centralized lubrication system or a double-line centralized lubrication system or a progressive centralized lubrication system.

[0019] Advantages of the present invention: When the lubrication-based equipment health management system of the present invention is in use, the temperature sensor and the vibration sensor will detect the temperature and vibration data of the equipment to be lubricated, especially the temperature and vibration data near the lubrication points. If the temperature is higher than the set value or the vibration data threshold exceeds the set threshold, based on the combination of temperature and vibration waveforms and comparison with the database, the corresponding fault types can be inferred, such as poor lubrication, damage to the friction pair, etc., and an alarm will be sent in a timely manner through the equipment management platform. If the amount of lubricating grease added is less or excessive, the equipment management platform will control the centralized lubrication module to adopt an appropriate lubrication strategy to adjust the filling amount. The lubricating grease quality detection sensor can continuously and online detect the quality of the lubricating grease used inside the friction pair, such as data on moisture content, iron filings content, temperature, etc., and then determine whether the quality of the lubricating grease is qualified. When based on the detected lubricating grease quality situation and combined with the detection of the equipment status by the temperature sensor and the vibration sensor, the data of the three sensors are combined with each other, the specific fault type can be accurately judged, whether the lubricating grease is old and needs to be replaced with new grease, or the equipment itself is worn, or the amount of lubricating grease is inappropriate, etc. The equipment management platform can give corresponding adjustment instructions to the centralized lubrication module and the waste grease discharge module, adjust the filling amount of the new lubricating grease, the discharge amount of the old lubricating grease, and the total amount of the lubricating grease inside the friction pair, etc., to realize functions such as equipment status monitoring, analysis and diagnosis, intelligent lubrication on demand, operation and maintenance, and lubrication management, and reduce the manual labor intensity and cost as much as possible. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 FIG. 1 is a schematic structural diagram of Embodiment 1 of a lubrication-based equipment health management system of the present invention; Figure 2 is Figure 1 a schematic working principle diagram of the corresponding automatic grease change module; Figure 3 is Figure 1 a system block diagram of the corresponding working principle; Figure 4 FIG. 4 is a schematic detection principle diagram of a fault during vibration detection; Figure 5 FIG. 5 is a schematic structural diagram of Embodiment 2 of a lubrication-based equipment health management system of the present invention; In the figure: 1 - automatic grease change module, 11 - centralized lubrication module, 111 - lubricating pump, 112 - distributor, 12 - waste grease discharge module, 2 - detection module, 21 - lubricating grease quality detection sensor, 22 - temperature sensor, 23 - vibration sensor, 24 - data acquisition module, 25 - end detection sensor, 26 - control gateway; 31 - equipment management platform, 32 - display hardware. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, 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 of the embodiments. Usually, the components of the embodiments of the present invention described and illustrated herein can be arranged and designed in various different configurations.

[0022] Therefore, the following 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 merely represents 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.

[0023] 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 "comprising", "including" 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 further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising one..." does not exclude the presence of additional identical elements in the process, method, article or device including the said element.

[0024] The features and performance of the present invention will be further described in detail below with reference to the embodiments.

[0025] Embodiment 1 of a lubrication-based equipment health management system of the present invention: As Figure 1-2 shown, the system mainly includes an automatic grease change module 1, a detection module 2 and a customer terminal.

[0026] As Figure 2As shown, the automatic grease changing module 1 includes a centralized lubrication module 11 for adding new lubricating grease to the equipment and a waste grease discharging module 12 for sucking out the waste grease in the equipment. The centralized lubrication module 11 includes a lubricating pump 111 and a dispenser 112. The lubricating pump 111 includes a lubrication controller. The waste grease discharging module 12 includes a fat extraction pump and a waste grease collection bucket. The fat extraction pump includes a fat extraction controller. The lubricating pump 111 includes an oil tank, and an oil level detection sensor for detecting the lubricating grease level therein is provided on the oil tank. The setting of the oil level detection sensor enables maintenance personnel to timely know whether there is a lack of grease in the oil tank of the lubricating pump 111, so as to replenish grease in time when there is a lack of grease. The oil level detection sensor is a laser opposed sensor, and the oil level detection sensor transmits data to the lubrication controller for final feedback to the equipment management platform 31. The fat extraction pump is an electric fat suction and discharge device or the fat extraction pump includes a hydraulic power pump and a liquid-controlled fat suction and discharge device. The centralized lubrication module 11 is a single-line centralized lubrication system or a double-line centralized lubrication system or a progressive centralized lubrication system.

[0027] The outlet of the dispenser 112 is connected to each lubrication point through a lubrication pipeline. A terminal detection sensor 25 for detecting whether the lubricating grease is flowing is provided at one end of the lubrication pipeline close to the lubrication point. The terminal detection sensor 25 transmits data to the lubrication controller. By setting the terminal detection sensor 25, the main problem to be solved is that although the existing centralized lubrication system is running, due to reasons such as poor fluidity of the lubricating grease, long pipelines, and blockage of lubrication points, the lubricating grease actually fails to be filled to the lubrication points as set, resulting in misjudgment by maintenance personnel. The harm degree is far greater than that of not installing a centralized lubrication system. By installing the terminal detection sensor 25 on the oil pipe close to the lubrication point, "eyes" are installed at the lubrication point, enabling maintenance personnel to accurately know the actual situation of the lubricating grease filled at the lubrication point and meeting the requirements of effective lubrication. The terminal detection sensor 25 includes a throttling structure formed by the transformation from a large-volume chamber to a small-volume chamber and a pressure sensor provided in the large-volume chamber for detecting the pressure of the lubricating grease in the large-volume chamber. When the data detected by the pressure sensor reaches the set pressure, it means that the lubricating grease supply stops at the lubrication point.

[0028] In the gas embodiment, the system further includes a grease replenishment module. The grease replenishment module includes a grease storage barrel and an electric grease replenishment pump. The electric grease replenishment pump includes a grease replenishment controller. The grease replenishment controller transmits and receives data with the equipment management platform 31 through a wireless communication module. When the oil level detection module 2 of the lubrication controller detects that the oil level reaches the lowest set value, the equipment management platform 31 transmits a grease replenishment instruction to the grease replenishment controller to control the operation of the electric grease replenishment pump, so as to pressurize and pump the grease in the grease storage barrel into the fuel tank of the lubrication pump 111. When the oil level detection module 2 detects that the oil level reaches the highest set value, the equipment management platform 31 transmits a stop grease replenishment instruction to the grease replenishment controller to control the electric grease replenishment pump to stop operating. After setting the grease replenishment module, the centralized lubrication system can work for a longer time without manual grease replenishment, thereby reducing the maintenance frequency and saving labor costs.

[0029] As Figure 1 shown, a plunger action detection module 2 for detecting whether the plunger of the dispenser 112 moves is installed on the dispenser 112. The setting of the plunger action detection module 2 can mainly timely know the operating state of the dispenser 112, so as to timely know and display the fault location when the dispenser 112 fails, so that maintenance personnel can troubleshoot the fault earlier. The plunger action detection module 2 includes a Hall sensor and a permanent magnet part installed on the plunger and used in cooperation with the Hall sensor.

[0030] The detection module 2 includes a grease quality detection sensor 21 for detecting the quality of the used grease in the friction pair of the equipment, as well as a temperature sensor 22 and a vibration sensor 23 for detecting the temperature and vibration conditions of the equipment. Data acquisition modules 24 are respectively provided on the grease quality detection sensor 21, the temperature sensor 22 and the vibration sensor 23. The grease quality detection sensor 21 transmits data to the lubrication controller.

[0031] The client terminal includes display hardware 32 and a device management platform 31. The device management platform 31 includes a wireless communication module and a data processing module. The lubrication controller and the liposuction controller exchange data with the device management platform 31 through the wireless communication module; the temperature sensor 22 and the vibration sensor 23 transmit data to the device management platform 31 through the wireless communication module of the control gateway 26. During operation, the client terminal can obtain the grease status and equipment operation status data, including the equipment fault type and corresponding location information, and the degree of grease deterioration, according to the vibration, temperature and grease quality values fed back by the above three sensors, after analysis by the data processing module, and then make a fault alarm, or form a new grease replacement strategy instruction to send to the lubrication controller and the liposuction controller to control the lubrication pump 111 and the liposuction pump to execute the corresponding grease replacement strategy. The data transmitted by the lubrication controller to the device management platform 31 include the start and stop time of the lubrication pump 111, the grease supply, the grease pressure of the main line, the data of each terminal detection sensor 25, and the data of the grease quality detection sensor 21. The feedback of the grease pressure data of the main line can determine whether the centralized lubrication module 11 itself has a fault, such as whether the pipeline is blocked. The grease quality detection sensor 21 includes a humidity detection module 2 for detecting the moisture content in the grease, an iron chip detection module 2 for detecting the iron chip content in the grease, and a temperature detection module 2 for detecting the temperature of the grease. The wireless communication module includes LORA or zigbee or 4G. The vibration sensor 23 and the temperature sensor 22 use a temperature-vibration integrated sensor.

[0032] When the lubrication-based equipment health management system of the present invention is in use, the temperature sensor 22 and the vibration sensor 23 will detect the temperature and vibration data of the equipment to be lubricated, especially the temperature and vibration data near the lubrication points. If the temperature is higher than the set value or the vibration data threshold exceeds the set threshold, by combining the temperature and the vibration waveform and comparing with the database, the corresponding fault types can be inferred, such as poor lubrication, damage of the friction pair, etc., and an alarm will be sent in time through the equipment management platform 31. If the amount of lubricating grease added is less or excessive, the equipment management platform 31 will control the centralized lubrication module 11 to adopt appropriate lubrication strategies to adjust the addition amount; while the lubricating grease quality detection sensor 21 can detect the quality of the lubricating grease used inside the friction pair in real time online, such as data on moisture content, iron filings content, temperature, etc., and then judge whether the quality of the lubricating grease is qualified. When judging according to the detected lubricating grease quality situation and combining with the detection of the equipment state by the temperature sensor 22 and the vibration sensor 23, the data of the three sensors can be combined to accurately judge what specific fault type it is, whether the lubricating grease is old and needs to be replaced with new grease, whether the equipment itself is worn, or whether the amount of lubricating grease is inappropriate, etc. The equipment management platform 31 can give corresponding adjustment instructions to the centralized lubrication module 11 and the waste grease discharge module 12 to adjust the addition amount of new lubricating grease, the discharge amount of old lubricating grease, and the total amount of lubricating grease inside the friction pair, etc., so as to realize functions such as equipment state monitoring, analysis and diagnosis, intelligent lubrication on demand, operation and maintenance, and lubrication management, and reduce the manual labor intensity and cost as much as possible.

[0033] 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 shall be subject to the claims. All equivalent structural changes made by using the description and drawings of the present invention shall be equally included in the protection scope of the present invention.

Claims

1. A lubrication-based equipment health management system, characterized in that, Comprising: An automatic grease changing module, including a centralized lubrication module for injecting new lubricating grease into the equipment and a waste grease discharging module for sucking out the waste grease in the equipment. The centralized lubrication module includes a lubrication pump and a distributor. The lubrication pump includes a lubrication controller. The waste grease discharging module includes a fat extraction pump and a waste grease collection bucket. The fat extraction pump includes a fat extraction controller; A detection module, including a grease quality detection sensor for detecting the quality of the used lubricating grease in the friction pair of the equipment, and a temperature sensor and a vibration sensor for detecting the temperature and vibration conditions of the equipment. Data acquisition modules are respectively provided on the grease quality detection sensor, the temperature sensor and the vibration sensor. The grease quality detection sensor transmits data to the lubrication controller; A customer terminal, including a display hardware and an equipment management platform. The equipment management platform includes a wireless communication module and a data processing module. The lubrication controller and the fat extraction controller exchange data with the equipment management platform through the wireless communication module; The temperature sensor and the vibration sensor transmit data to the equipment management platform through the wireless communication module of the control gateway; During operation, the customer terminal analyzes the vibration, temperature and grease quality values fed back by the above three sensors through the data processing module, and can obtain the grease state and equipment operation state data, including the equipment failure type and corresponding position information, and the degree of grease deterioration. Then, it conducts a fault alarm or forms a new grease changing strategy instruction and sends it to the lubrication controller and the fat extraction controller to control the lubrication pump and the fat extraction pump to execute the corresponding grease changing strategy.

2. The device health management system based on lubrication according to claim 1, characterized in that, The outlet of the distributor is connected to each lubrication point through a lubrication pipeline. One end of the lubrication pipeline close to the lubrication point is provided with an end detection sensor for detecting whether the lubricating grease is flowing. The end detection sensor transmits data to the lubrication controller.

3. The device health management system based on lubrication according to claim 2, characterized in that, The end detection sensor includes a throttling structure formed by the transformation from a large-volume chamber to a small-volume chamber and a pressure sensor arranged in the large-volume chamber for detecting the pressure of the lubricating grease in the large-volume chamber. When the data detected by the pressure sensor reaches the set pressure, it means that the lubricating grease supply reaches the lubrication point.

4. The device health management system based on lubrication according to claim 2, characterized in that, The data transmitted by the lubrication controller to the equipment management platform includes the start and stop time of the lubrication pump operation, the grease supply volume, the lubricating grease pressure of the main pipeline, the data of each end detection sensor, and the data of the grease quality detection sensor.

5. A lubrication-based equipment health management system according to claim 1, wherein The lubrication pump includes an oil tank, and an oil level detection sensor for detecting the lubricating grease level in the oil tank is provided on the oil tank.

6. The device health management system based on lubrication according to claim 5, wherein The oil level detection sensor is a laser opposed sensor. The oil level detection sensor transmits data to the lubrication controller and finally feeds it back to the equipment management platform.

7. The device health management system based on lubrication according to claim 6, characterized in that, It includes a grease replenishment module. The grease replenishment module includes a grease storage barrel and an electric grease replenishment pump. The electric grease replenishment pump includes a grease replenishment controller. The grease replenishment controller transmits and receives data with the equipment management platform through a wireless communication module. 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 grease replenishment controller to control the operation of the electric grease replenishment pump, so as to pressurize and pump the grease in the grease storage barrel into the fuel tank of the lubrication pump. 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 grease replenishment controller to control the electric grease replenishment pump to stop operating.

8. An equipment health management system based on lubrication according to claim 1, characterized in that, The liposuction pump is an electric suction and fat drainage device.

9. A lubrication-based equipment health management system according to claim 1, wherein, The liposuction pump includes a hydraulic power pump and a liquid-controlled suction and fat drainage device.

10. An equipment health management system based on lubrication according to claim 1, characterized in that, A plunger action detection module for detecting whether the plunger of the dispenser acts is installed on the dispenser.

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