Intelligent lubricating grease supply monitoring system

Abstract

The invention discloses an intelligent lubricating grease supply monitoring system, and belongs to the technical field of equipment maintenance, the intelligent lubricating grease supply monitoring system comprises a master controller, an intelligent oil injection pump and mechanical equipment, the master controller integrates data acquisition, oil injection strategy generation, oil injection regulation and control and execution modules, and an oil injection unit is integrated in the mechanical equipment; the data acquisition module acquires operation parameters of a lubricating part, and the oil injection strategy generation module determines the partial oil injection amount, the partial oil injection frequency, the single oil injection amount and the single oil injection frequency according to the operation parameters; the oil injection regulation and control module sets an updating period for an oil injection unit, analyzes an oil injection evaluation value and an oil injection frequency value, draws a regulation and evaluation value change broken line graph, and regulates oil injection parameters according to a regulation and evaluation judgment value; the execution module controls the intelligent oiling pump to deliver oil and the oiling unit to distribute lubricating grease; the system can collect equipment operation data in real time, accurately formulate an oil injection strategy, dynamically adjust oil injection parameters, avoid lubrication abnormity, reduce equipment wear, reduce maintenance cost, and improve equipment reliability and production efficiency.

Description

Technical Field

[0001] The invention belongs to the technical field of equipment maintenance, and in particular relates to an intelligent grease supply monitoring system. Background Art

[0002] During the operation of various industrial equipment, the lubrication condition of the equipment is crucial to its performance, lifespan and stability. As a key link in ensuring the normal operation of mechanical equipment, lubrication plays an indispensable role in reducing friction loss and lowering the risk of equipment failure.

[0003] Traditional equipment lubrication methods often use fixed oil injection cycles and injection volumes, which cannot be adjusted in real time according to the actual operating conditions of the equipment. They are prone to insufficient or excessive lubrication, which accelerates the wear of equipment components.

[0004] The current lubrication system has difficulty in monitoring the lubrication status of equipment in real time and cannot detect potential lubrication problems in time, which in turn affects product quality and the smooth execution of production plans. To this end, we propose an intelligent grease supply monitoring system. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent grease supply monitoring system to solve the problems raised in the above background technology.

[0006] To achieve the above-mentioned object, the present invention provides the following technical solutions: an intelligent grease supply monitoring system, comprising: a main controller, an intelligent oil injection pump and mechanical equipment;

[0007] The main controller is integrated with a data acquisition module, an oil injection strategy generation module, an oil injection control module, and an execution module; the mechanical equipment is integrated with an oil injection unit;

[0008] Data acquisition module: used to collect operating parameters of the lubrication parts of mechanical equipment; lubrication parts are parts that need to be lubricated to reduce friction loss to ensure normal operation of the equipment;

[0009] Oil injection strategy generation module: Analyzes the operating parameters, action switching times, load value, and action frequency of the lubrication parts to determine the local oil injection amount and injection frequency of the lubrication parts, and analyzes the single oil injection amount and single injection frequency of the oil injection unit based on this;

[0010] Oil injection control module: Set an update cycle for the oil injection unit, analyze the oil injection evaluation value and injection frequency value of the lubrication part during the update cycle, obtain the adjustment evaluation value, and draw a line graph of the adjustment evaluation value change; by analyzing the characteristics of the line graph, obtain the adjustment evaluation judgment value, and use this value to determine whether to update the lubrication part's local oil injection amount and local injection frequency. If updated, recalculate the single oil injection amount and single injection frequency of the oil injection unit;

[0011] Execution module: controls the intelligent oil injection pump to deliver grease to the oil injection unit.

[0012] Preferably, the main controller, the intelligent oil injection pump and the mechanical equipment are in communication connection with each other; the main controller is responsible for controlling the intelligent oil injection pump to supply grease to the mechanical equipment;

[0013] The oil injection unit integrated in the mechanical equipment is responsible for distributing the grease input into the mechanical equipment to various lubrication parts; the lubrication parts include: the connection points of moving parts, the bearing installation points, the contact points of sliding parts, the contact points between cam and follower, and the seal installation points.

[0014] Preferably, the specific implementation process of the data acquisition module is:

[0015] The factory area is divided into several supply zones, each of which is equipped with an intelligent oil injection pump and several mechanical equipment;

[0016] For each supply area, parameter sensors are installed at each lubrication point of each mechanical equipment in the supply area to collect the operating parameters of each lubrication point; the parameter sensors include: temperature sensor, pressure sensor, vibration sensor, speed sensor, load sensor; the operating parameters include: temperature, pressure, vibration frequency, speed, and load.

[0017] Preferably, the specific process of the oil injection strategy generation module analyzing the oil injection amount of the lubrication part is:

[0018] When the mechanical equipment is started, the oil filling matching period is set, and the operating parameters of each lubrication part are obtained in real time. The average value of each operating parameter within the matching period is calculated to obtain the operating mean value;

[0019] For each operating parameter, several operation mean intervals are preset, each operation mean interval corresponds to an operation extreme value, and the corresponding operation extreme value is output by matching the operation mean of each operating parameter with the corresponding interval;

[0020] A weight coefficient is assigned to the extreme value corresponding to each operating parameter, and the oil injection evaluation value is obtained by multiplying all the operating parameters of the lubrication part by the corresponding weight coefficient and adding them together;

[0021] Several oil injection evaluation value intervals are preset, each of which corresponds to a partial oil injection amount. By matching the oil injection evaluation value with all the oil injection evaluation value intervals, the corresponding partial oil injection amount Q is output.

[0022] Preferably, the specific process of the oil injection strategy generation module analyzing the injection frequency of the lubrication part is:

[0023] For each lubrication part, the number of switching motion modes within the matching period is counted. The motion modes include: extension, contraction, rotation, and swing. The dynamic switching frequency value PZ is obtained by dividing the number of motion mode switching times by the matching period duration.

[0024] Obtain the maximum load value and minimum load value of the lubrication part during the matching period, and obtain the load variation amplitude FZ by subtracting the minimum load value from the maximum load value;

[0025] For each motion mode of the lubrication part, the maximum speed value and minimum amplitude value of the motion model within the matching period are obtained, and the dynamic change value is obtained by subtracting the two. Then, the dynamic change values of all the motion modes of the lubrication part are averaged to obtain the dynamic change mean value BZ;

[0026] The injection frequency value ZP is obtained by combining the dynamic shear frequency value PZ, load change amplitude FZ, dynamic change mean BZ and oil injection amount Q corresponding to the lubrication part using the formula: ZP = (PZ×a1+FZ×a2+BZ×a3) / Q×a4, where a1, a2, and a3 are preset weight coefficients;

[0027] Several injection frequency value intervals are preset, each injection frequency value interval corresponds to a partial injection frequency, and the corresponding partial injection frequency F is output by matching the injection frequency value with all injection frequency value intervals.

[0028] Preferably, the specific process of the oil injection strategy generation module analyzing the single oil injection amount and single injection frequency of the oil injection unit is:

[0029] For each oiling unit, the total oiling amount required for each lubricating part in the oiling unit is summarized and marked as Qi, i = 1, 2, ..., n; i is the number of the lubricating part, and n is the total number of lubricating parts;

[0030] Obtain the length C and diameter R of the oil pipeline between the mechanical equipment corresponding to the oil injection unit and the intelligent oil injection pump in the corresponding supply area, as well as the oil injection error rate W of the intelligent oil injection pump. After normalization, use the formula: k = C × s1 + R × s2 + W × s3 to obtain the loss evaluation value k, where s1, s2, and s3 are preset weight coefficients.

[0031] Preset multiple loss evaluation value intervals, each loss evaluation value interval corresponds to a loss rate, match the loss evaluation value with all loss evaluation value intervals, and output the corresponding loss rate q;

[0032] Using the formula: Get the single oil injection amount QD, where wi is the preset weight coefficient corresponding to the oil injection amount of each part;

[0033] Using the formula: Get the single note frequency FD;

[0034] For each oil injection unit, its corresponding single oil injection amount and single injection frequency are sent to the execution module. The execution module controls the intelligent oil injection pump to deliver grease according to the single injection frequency and single oil injection amount corresponding to the oil injection unit; then the oil injection unit injects grease into each lubrication part according to the corresponding partial oil injection amount and partial injection frequency of each lubrication part.

[0035] Preferably, the specific process of the oil injection control module analyzing the adjustment evaluation value and drawing a line graph of the adjustment evaluation value change is as follows:

[0036] For each oiling unit, an oiling update cycle is set. Whenever the oiling update cycle is reached, the single oiling amount and single oiling frequency data corresponding to the oiling unit and the partial oiling amount and partial oiling frequency data corresponding to each lubrication part of the oiling unit are recalculated, and the oiling unit and lubrication parts are re-oiled based on the above data;

[0037] For each update cycle, the duration corresponding to the update cycle is divided into several monitoring periods. For each lubrication part, the corresponding oil injection evaluation value and injection frequency value in each monitoring period are calculated, and weight coefficients are assigned to the oil injection evaluation value and injection frequency value respectively. Subsequently, the oil injection evaluation value and injection frequency value corresponding to the lubrication part in the monitoring period are multiplied by the corresponding weight coefficients and added together to obtain the adjustment evaluation value;

[0038] A two-dimensional rectangular coordinate system is established, with the vertical axis being the adjustment evaluation value and the horizontal axis being time. The adjustment evaluation values corresponding to each monitoring period are substituted into the coordinate system in chronological order to obtain several data points. Adjacent data points in the coordinate system are then connected with line segments to obtain a broken line showing the change in the adjustment evaluation value.

[0039] Preferably, the specific process of the oil injection control module analyzing the adjustment evaluation judgment value is:

[0040] Starting from the initial moment of the update cycle, a sliding window is set in the adjustment value change line chart. The window size is a number of monitoring periods. After each new monitoring period ends, the monitoring period is included in the sliding window and the earliest monitoring period is removed. This process of adding and removing is defined as the update of the sliding window.

[0041] When the sliding window is updated, the mean of the adjustment evaluation values corresponding to each monitoring period in the sliding window is calculated and recorded as the adjustment evaluation mean;

[0042] According to the adjustment evaluation mean and the adjustment evaluation value corresponding to each monitoring period, the standard deviation calculation method is used to calculate and obtain the adjustment evaluation fluctuation value DP;

[0043] By performing linear regression analysis on the adjustment evaluation value within the sliding window, the slope of the adjustment evaluation value changing over time is obtained, which is recorded as the adjustment evaluation trend value TQ;

[0044] Extract the maximum and minimum adjustment evaluation values within the sliding window, and obtain the adjustment evaluation range value TC by subtracting the minimum adjustment evaluation value from the maximum adjustment evaluation value;

[0045] After normalizing the adjustment evaluation fluctuation value DP, the adjustment evaluation trend value TQ and the adjustment evaluation range value TC, the adjustment evaluation judgment value TPZ is obtained using the formula: TPZ = DP×c1+TQ×c2+TC×c3; where c1, c2, and c3 are preset weight coefficients.

[0046] Preferably, the specific process of the oil injection control module determining whether to update the oil injection amount and injection frequency of the lubrication part is:

[0047] Preset the upper and lower thresholds SZ and XZ for adjusting the evaluation judgment, and compare the adjustment evaluation judgment value TPZ with the preset upper and lower thresholds for adjusting the evaluation judgment;

[0048] If the adjustment evaluation judgment value is greater than the corresponding upper limit threshold, it is judged that the lubrication is excessive and the oil injection is updated using the formula: The reduced partial oil injection amount QJ and the reduced partial oil injection frequency FJ are obtained, where r1 is the reduction ratio of the partial oil injection amount; RQmax is the maximum allowable reduction ratio of the partial oil injection amount, Q is the original partial oil injection amount; r2 is the reduction ratio of the partial oil injection frequency, RFmax is the maximum allowable reduction ratio of the partial oil injection frequency, and F is the original partial oil injection frequency;

[0049] By sending the reduced oil filling amount and reduced oil filling frequency corresponding to the lubrication part to the oil filling unit, an oil filling reduction instruction is generated at the same time. After receiving the instruction, the oil filling unit re-oils the lubrication part according to the reduced oil filling amount and reduced oil filling frequency corresponding to the lubrication part;

[0050] If the adjustment evaluation value is less than the corresponding lower limit threshold, it is judged that the lubrication is insufficient and the oil filling is updated using the formula: Get the partial oil injection amount QG and the partial oil injection frequency FG, where h1 is the partial oil injection amount increase ratio; HQmax is the preset maximum allowable oil injection amount increase ratio, h2 is the partial oil injection frequency increase ratio, and HFmax is the preset maximum allowable oil injection frequency increase ratio;

[0051] By sending the additional oil filling amount and additional oil filling frequency corresponding to the lubrication part to the oil filling unit, an oil filling increase instruction is generated at the same time. After receiving the instruction, the oil filling unit re-oils the lubrication part according to the additional oil filling amount and additional oil filling frequency FG corresponding to the lubrication part;

[0052] If the adjustment evaluation judgment value is between the upper and lower threshold values, the lubrication is determined to be stable. At this time, the lubrication part continues to maintain the current oil filling amount and frequency for oil filling.

[0053] Preferably, the specific process of the oil injection control module recalculating the single oil injection amount and single injection frequency of the oil injection unit is:

[0054] For each oiling unit, if the corresponding partial oiling amount and partial oiling frequency of each lubrication part corresponding to the oiling unit are updated, the single oiling amount and single oiling frequency are recalculated according to the corresponding partial oiling amount and partial oiling frequency of each lubrication part after update, and the oiling update instruction of the oiling unit is generated and sent to the execution module. The execution module performs the oiling operation on the oiling unit according to the recalculated single oiling amount and single oiling frequency of the oiling unit.

[0055] Compared with the prior art, the present invention has the following beneficial effects:

[0056] (1) This intelligent grease supply monitoring system, the data acquisition module collects operating parameters such as temperature, pressure, and vibration frequency in real time by installing multiple sensors at various lubrication points; the oil injection strategy generation module calculates the mean value, matches the extreme value and combines the analysis of the oil injection evaluation value based on these parameters to determine the precise local oil injection amount; for the robot arm joints that frequently extend and contract, the dynamic switching frequency value is obtained by counting the number of action mode switching times, and the injection frequency value is calculated by combining the load change amplitude, the dynamic change mean value and the oil injection amount, and then the appropriate local injection frequency is matched; this enables the oil injection strategy to closely fit the actual working conditions of the various lubrication points of the equipment, avoid insufficient or excessive lubrication, effectively reduce the wear of equipment components, and extend the service life of the equipment.

[0057] (2) This intelligent grease supply monitoring system has an oiling unit with an update cycle, which periodically recalculates various oiling parameters and can keenly capture changes in the lubrication status of the equipment; the monitoring period is divided within the update cycle, and the oiling evaluation value and injection frequency value are calculated and analyzed. The sliding window technology is used to obtain the adjustment evaluation mean value, fluctuation value, etc., and the adjustment evaluation judgment value is obtained. After comparing with the preset threshold, the oiling amount and frequency are accurately adjusted to effectively avoid excessive or insufficient lubrication, prevent equipment failure, and ensure stable operation of the equipment; based on the sliding window analysis results, the oiling strategy is dynamically adjusted to adapt to complex working conditions, so that the equipment can always maintain good lubrication and improve equipment reliability and life; when the oiling parameters of the lubrication part change, the oiling control module recalculates and instructs the execution module to accurately oil, and the oiling units are adjusted in a coordinated manner to achieve overall optimization, reduce equipment wear and maintenance costs, improve production efficiency, and significantly reduce the risk of production interruption caused by lubrication problems.

[0058] (3) This intelligent grease supply monitoring system calculates the loss evaluation value and loss rate through factors such as the length of the oil pipeline, the diameter of the pipe and the oil injection error rate, and then determines the reasonable single oil injection amount and single injection frequency; the execution module controls the intelligent oil injection pump to accurately inject oil, and the oil injection unit accurately distributes grease; it is convenient to optimize the oil injection plan, reduce the loss of grease during the transportation process, improve the grease utilization efficiency, and reduce the procurement cost; at the same time, it reduces equipment wear and the number of repairs, thereby reducing maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1 It is a structural block diagram of the present invention;

[0060] Figure 2 is a flow chart of the main controller of the present invention;

[0061] Figure 3 It is a line graph of the change of the adjustment evaluation value of the present invention. DETAILED DESCRIPTION

[0062] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0063] Example 1

[0064] See also Figure 1-Figure 3 , the present invention provides an intelligent grease supply monitoring system, comprising: a main controller, an intelligent oil injection pump and mechanical equipment;

[0065] The main controller, the intelligent oil injection pump and the mechanical equipment are connected to each other, and the main controller is responsible for controlling the intelligent oil injection pump to supply grease to the mechanical equipment;

[0066] The main controller is integrated with data acquisition module, oil injection strategy generation module, oil injection control module and execution module; the mechanical equipment is integrated with oil injection unit;

[0067] The data acquisition module divides the factory area into several supply zones. Each supply zone is equipped with an intelligent oil injection pump and several mechanical equipment. The module collects the operating parameters of the lubrication parts of the mechanical equipment. The specific process is as follows:

[0068] The factory area is divided into several supply zones, each equipped with an intelligent oil injection pump and several mechanical equipment. The intelligent oil injection pump is used to control the amount of grease distributed to each equipment in the supply zone and is connected to the oil tank.

[0069] For each piece of machinery, specific parts that require oiling to reduce friction loss to ensure normal operation are marked as lubrication points. The oiling unit is responsible for accurately distributing the grease input into the machinery to each lubrication point.

[0070] Lubrication areas include: joints of moving parts, bearing installations, contact points of sliding parts, contact points between cams and followers, and seal installations;

[0071] Connections between moving parts: the connection between gears and shafts, the meshing parts between chains and sprockets, etc.

[0072] The bearing installation places are: inner ring, outer ring, friction parts between rolling element and cage of rolling bearing, etc.

[0073] The contact points of sliding parts are: piston, cylinder wall, slider, guide rail, etc.

[0074] Seal installation location: the area where oil seals, sealing rings, etc. are located;

[0075] For each supply area, parameter sensors are installed at each lubrication point of each mechanical equipment in the supply area to collect the operating parameters of each lubrication point; parameter sensors include: temperature sensors, pressure sensors, vibration sensors, speed sensors, load sensors, etc.; operating parameters include: temperature, pressure, vibration frequency, speed, load, etc.

[0076] The oil injection strategy generation module analyzes the operating parameters, action switching times, load value, and action frequency of the lubrication parts to determine the local oil injection amount and frequency of the lubrication parts. Based on this, it analyzes the single oil injection amount and frequency of the oil injection unit. The specific process is as follows:

[0077] When the mechanical equipment is started, the oil filling matching period is set, and the operating parameters of each lubrication part are obtained in real time. The average value of each operating parameter within the matching period is calculated to obtain the operating mean value;

[0078] For each operating parameter, several operation mean intervals are preset, each operation mean interval corresponds to an operation extreme value, and the corresponding operation extreme value is output by matching the operation mean of each operating parameter with the corresponding interval;

[0079] A weight coefficient is assigned to the extreme value corresponding to each operating parameter, and the oil injection evaluation value is obtained by multiplying all the operating parameters of the lubrication part by the corresponding weight coefficient and adding them together;

[0080] Several oiling evaluation value intervals are preset, each of which corresponds to a partial oiling amount, where the partial oiling amount is a single oiling amount based on the oiling frequency. By matching the oiling evaluation value with all the oiling evaluation value intervals, the corresponding partial oiling amount Q is output;

[0081] For each lubrication part, the number of switching motion modes within the matching period is counted. The motion modes include: extension, contraction, rotation, swing, etc. The dynamic switching frequency value PZ is obtained by dividing the number of motion mode switching times by the matching period duration.

[0082] Obtain the maximum load value and minimum load value of the lubrication part during the matching period, and obtain the load variation amplitude FZ by subtracting the minimum load value from the maximum load value;

[0083] For each motion mode of the lubrication part, the maximum speed value and minimum amplitude value of the motion model within the matching period are obtained, and the dynamic change value is obtained by subtracting the two. Then, the dynamic change values of all the motion modes of the lubrication part are averaged to obtain the dynamic change mean value BZ;

[0084] The injection frequency value ZP is obtained by combining the dynamic shear frequency value PZ, load change amplitude FZ, dynamic change mean BZ and oil injection amount Q corresponding to the lubrication part using the formula: ZP = (PZ×a1+FZ×a2+BZ×a3) / Q×a4, where a1, a2, and a3 are preset weight coefficients;

[0085] Several injection frequency value intervals are preset, each of which corresponds to a partial injection frequency. By matching the injection frequency value with all injection frequency value intervals, the corresponding partial injection frequency F is output; the larger the upper and lower bounds of the injection frequency value interval, the greater the corresponding partial injection frequency and the shorter the oil injection time interval;

[0086] For each oiling unit, the total oiling amount required for each lubricating part in the oiling unit is summarized and marked as Qi, i = 1, 2, ..., n; i is the number of the lubricating part, and n is the total number of lubricating parts;

[0087] Obtain the length C and diameter R of the oil pipeline between the mechanical equipment corresponding to the oil injection unit and the intelligent oil injection pump in the corresponding supply area, as well as the oil injection error rate W of the intelligent oil injection pump. After normalization, use the formula: k = C × s1 + R × s2 + W × s3 to obtain the loss evaluation value k, where s1, s2, and s3 are preset weight coefficients.

[0088] Multiple loss evaluation value intervals are preset, each loss evaluation value interval corresponds to a loss rate, the loss evaluation value is matched with all loss evaluation value intervals, and the corresponding loss rate q is output; the larger the upper and lower bounds of the loss evaluation value interval are, the larger the corresponding loss rate q is;

[0089] Using the formula: Get the single oil injection amount QD, where wi is the preset weight coefficient corresponding to the oil injection amount of each part;

[0090] Using the formula: Get the single note frequency FD;

[0091] For each oil injection unit, its corresponding single oil injection amount and single injection frequency are sent to the execution module. The execution module controls the intelligent oil injection pump to deliver grease according to the single injection frequency and single oil injection amount corresponding to the oil injection unit; then the oil injection unit injects grease into each lubrication part according to the corresponding partial oil injection amount and partial injection frequency of each lubrication part.

[0092] It should be noted that when the equipment is turned on, the oiling strategy generation module obtains the operating parameters of the lubrication parts such as temperature, pressure, vibration frequency, speed, load, etc. in real time by setting the oiling matching period, and calculates the average value. Then, the average value is matched with the preset interval to obtain the extreme value, and then the oiling evaluation value is calculated in combination with the weight coefficient, so as to match the accurate local oiling amount. For the robotic arm joints that frequently extend and contract, the dynamic switching frequency value is obtained by counting the number of action mode switching times, and the injection frequency value is calculated in combination with the load change amplitude, dynamic change average value and oiling amount, and then the appropriate local injection frequency is matched. This enables the oiling strategy to closely fit the actual working conditions of the various lubrication parts of the equipment, avoid insufficient or excessive lubrication, effectively reduce the wear of equipment components, and extend the service life of the equipment.

[0093] For each oiling unit, the module summarizes the local oiling amount of each lubrication part, and at the same time obtains the length value, pipe diameter value and oiling error rate of the oil pipeline, and calculates the loss evaluation value and loss rate; in the equipment group of a large factory, the distance between different equipment and the oiling pump and the pipeline specifications vary greatly. The module can optimize the oiling plan based on these factors; the single oiling amount and single injection frequency are calculated through formulas to ensure that the amount of grease delivered by the intelligent oiling pump is accurate and the oiling frequency is reasonable; the execution module controls the oiling according to these parameters, and the oiling unit then accurately distributes the grease to each lubrication part, thereby improving the utilization efficiency of the grease and reducing costs.

[0094] The oil injection control module sets an update cycle for the oil injection unit. During the update cycle, it analyzes the oil injection evaluation value and injection frequency value of the lubrication part to obtain the adjustment evaluation value and draws a line graph of the adjustment evaluation value change. By analyzing the characteristics of the line graph, it obtains the adjustment evaluation judgment value and uses it to determine whether to update the lubrication part's local oil injection amount and local injection frequency. If updated, the single oil injection amount and single injection frequency of the oil injection unit are recalculated. The specific process is as follows:

[0095] For each oiling unit, set an oiling update cycle. Whenever the oiling update cycle is reached, recalculate the single oiling amount and single oiling frequency data corresponding to the oiling unit and the partial oiling amount and partial oiling frequency data corresponding to each lubrication part of the oiling unit. Based on the above data, re-oil the oiling unit and the lubrication parts.

[0096] For each update cycle, the duration corresponding to the update cycle is divided into several monitoring periods. For each lubrication part, the corresponding oil injection evaluation value and injection frequency value in each monitoring period are calculated, and weight coefficients are assigned to the oil injection evaluation value and injection frequency value respectively. Subsequently, the oil injection evaluation value and injection frequency value corresponding to the lubrication part in the monitoring period are multiplied by the corresponding weight coefficients and added together to obtain the adjustment evaluation value;

[0097] Establish a two-dimensional rectangular coordinate system, with the vertical axis being the adjustment value and the horizontal axis being time. Substitute the adjustment value corresponding to each monitoring period into the coordinate system in chronological order to obtain several data points. Then connect the adjacent data points in the coordinate system with line segments to obtain the adjustment value change line, such as Figure 3 ;

[0098] Starting from the initial moment of the update cycle, a sliding window is set in the adjustment value change line chart. The window size is a number of monitoring periods. After each new monitoring period ends, the monitoring period is included in the sliding window and the earliest monitoring period is removed. This process of adding and removing is defined as the update of the sliding window.

[0099] When the sliding window is updated, the mean of the adjustment evaluation values corresponding to each monitoring period in the sliding window is calculated and recorded as the adjustment evaluation mean;

[0100] According to the adjustment evaluation mean and the adjustment evaluation value corresponding to each monitoring period, the standard deviation calculation method is used to calculate and obtain the adjustment evaluation fluctuation value DP;

[0101] By performing linear regression analysis on the adjustment evaluation value within the sliding window, the slope of the adjustment evaluation value changing over time is obtained, which is recorded as the adjustment evaluation trend value TQ;

[0102] Extract the maximum and minimum adjustment evaluation values within the sliding window, and obtain the adjustment evaluation range value TC by subtracting the minimum adjustment evaluation value from the maximum adjustment evaluation value;

[0103] After normalizing the adjustment evaluation fluctuation value DP, the adjustment evaluation trend value TQ, and the adjustment evaluation range value TC, the adjustment evaluation judgment value TPZ is obtained using the formula: TPZ = DP × c1 + TQ × c2 + TC × c3; where c1, c2, and c3 are preset weight coefficients;

[0104] The upper and lower thresholds SZ and XZ of the adjustment evaluation are preset. The upper and lower thresholds can be set by calculating the average value u and standard deviation f of the adjustment evaluation values over a period of time, and presetting the proportional coefficient m; the upper threshold SZ = u + mf, and the lower threshold XZ = u - mf;

[0105] By comparing the adjustment evaluation judgment value TPZ with the preset adjustment evaluation judgment upper and lower thresholds;

[0106] If the adjustment evaluation judgment value is greater than the corresponding upper limit threshold, it is judged that the lubrication is excessive and the oil injection is updated using the formula: The reduced partial oil injection amount QJ and the reduced partial oil injection frequency FJ are obtained, where r1 is the reduction ratio of the partial oil injection amount; RQmax is the maximum allowable reduction ratio of the partial oil injection amount, Q is the original partial oil injection amount; r2 is the reduction ratio of the partial oil injection frequency, RFmax is the maximum allowable reduction ratio of the partial oil injection frequency, and F is the original partial oil injection frequency;

[0107] By sending the reduced oil filling amount and reduced oil filling frequency corresponding to the lubrication part to the oil filling unit, an oil filling reduction instruction is generated at the same time. After receiving the instruction, the oil filling unit re-oils the lubrication part according to the reduced oil filling amount and reduced oil filling frequency corresponding to the lubrication part;

[0108] If the adjustment evaluation value is less than the corresponding lower limit threshold, it is judged that the lubrication is insufficient and the oil filling is updated using the formula: Get the partial oil injection amount QG and the partial oil injection frequency FG, where h1 is the partial oil injection amount increase ratio; HQmax is the preset maximum allowable oil injection amount increase ratio, h2 is the partial oil injection frequency increase ratio, and HFmax is the preset maximum allowable oil injection frequency increase ratio;

[0109] By sending the additional oil filling amount and additional oil filling frequency corresponding to the lubrication part to the oil filling unit, an oil filling increase instruction is generated at the same time. After receiving the instruction, the oil filling unit re-oils the lubrication part according to the additional oil filling amount and additional oil filling frequency FG corresponding to the lubrication part;

[0110] If the adjustment evaluation judgment value is between the upper and lower thresholds, the lubrication is considered stable, and the lubrication operation is continued for the lubrication part at the current oil filling amount and frequency.

[0111] For each oiling unit, if the corresponding partial oiling amount and partial oiling frequency of each lubrication part corresponding to the oiling unit are updated, the single oiling amount and single oiling frequency are recalculated according to the corresponding partial oiling amount and partial oiling frequency of each lubrication part after the update, and the oiling unit oiling update instruction is generated and sent to the execution module. The execution module performs the oiling operation on the oiling unit according to the recalculated single oiling amount and single oiling frequency of the oiling unit; wherein the corresponding partial oiling amount and partial oiling frequency after the update can be an increased partial oiling amount and an increased partial oiling frequency or a decreased partial oiling amount and a decreased partial oiling frequency.

[0112] It should be noted that the oil injection control module sets an update cycle for the oil injection unit, and periodically recalculates the single oil injection amount, single injection frequency, partial oil injection amount, and partial injection frequency. In large-scale chemical production equipment, the equipment operates continuously for a long time and the operating conditions are complex and changeable. By dividing the update cycle, it can respond to changes in the equipment's lubrication status in a timely manner.

[0113] In each update cycle, the monitoring period is further divided, and the oil injection evaluation value and injection frequency value of each lubrication part are calculated to obtain the adjustment evaluation value and draw a line chart; taking the bearing lubrication part of a chemical pump as an example, within the update cycle, if the pump load changes during the monitoring period, resulting in changes in the oil injection evaluation value and injection frequency value, the adjustment evaluation value will also change accordingly; based on the comparison results of the adjustment evaluation judgment value and the preset threshold value, the oil injection amount and oil injection frequency are accurately adjusted; when it is judged that over-lubrication is in progress, if the pump adjustment evaluation judgment value in a certain period is greater than the upper limit threshold, the partial oil injection amount and partial injection frequency are calculated and reduced according to the formula, effectively avoiding grease waste, preventing equipment failure caused by excessive lubrication, and ensuring stable equipment operation;

[0114] The sliding window technology is used to analyze the adjustment value change line chart to obtain the adjustment value mean, adjustment value fluctuation value, adjustment value trend value and adjustment value extreme value, and then obtain the adjustment value judgment value; this enables the system to dynamically adjust the oil injection strategy according to the actual operation trend of the equipment; in mining machinery, the equipment operating environment is harsh and the working conditions change at any time. For example, when a mining excavator is excavating ores of different hardness, the load and movement frequency of its various lubrication parts are constantly changing; through the real-time update of the sliding window, the system can capture subtle changes in the adjustment value; if the adjustment value trend value of a certain lubrication part shows that the lubrication effect is gradually getting worse when excavating hard ores, the adjustment value fluctuation value increases, and the adjustment value judgment value approaches the lower limit threshold, the system will promptly determine that the lubrication is insufficient, increase the local oil injection amount and injection frequency, and ensure that the equipment always maintains a good lubrication state under complex working conditions, thereby improving equipment reliability and service life;

[0115] When the local oil filling amount and local oil filling frequency of each lubrication part are updated, the oil filling control module recalculates the single oil filling amount and single oil filling frequency of the oil filling unit and sends instructions to the execution module; in the automobile manufacturing production line, multiple equipment work together, and each equipment contains multiple oil filling units and lubrication parts; if the oil filling demand of some lubrication parts of a certain equipment changes due to production process adjustments, the module will recalculate, and the execution module will control the intelligent oil filling pump to accurately adjust the oil delivery parameters, and the oil filling unit can also adjust the oil filling operation of each lubrication part accordingly; this overall collaborative optimization method ensures the efficient operation of the lubrication system of the entire production line equipment, reduces equipment wear and maintenance costs, improves production efficiency, and reduces the risk of production interruption due to lubrication problems.

[0116] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An intelligent grease supply monitoring system, comprising: The main controller, intelligent oil injection pump and mechanical equipment are characterized by: The main controller is integrated with a data acquisition module, an oil injection strategy generation module, an oil injection control module, and an execution module; the mechanical equipment is integrated with an oil injection unit; Data acquisition module: used to collect operating parameters of the lubrication parts of mechanical equipment; lubrication parts are parts that need to be lubricated to reduce friction loss to ensure normal operation of the equipment; Oil injection strategy generation module: Analyzes the operating parameters, action switching times, load value, and action frequency of the lubrication parts to determine the local oil injection amount and injection frequency of the lubrication parts, and analyzes the single oil injection amount and single injection frequency of the oil injection unit based on this; Oil injection control module: Set an update cycle for the oil injection unit, analyze the oil injection evaluation value and injection frequency value of the lubrication part during the update cycle, obtain the adjustment evaluation value, and draw a line graph of the adjustment evaluation value change; by analyzing the characteristics of the line graph, obtain the adjustment evaluation judgment value, and use this value to determine whether to update the lubrication part's local oil injection amount and local injection frequency. If updated, recalculate the single oil injection amount and single injection frequency of the oil injection unit; Execution module: controls the intelligent oil injection pump to deliver grease to the oil injection unit.

2. The intelligent grease supply monitoring system according to claim 1, characterized in that: The main controller, the intelligent oil injection pump and the mechanical equipment are in communication with each other; the main controller is responsible for controlling the intelligent oil injection pump to supply grease to the mechanical equipment; The oil injection unit integrated in the mechanical equipment is responsible for distributing the grease input into the mechanical equipment to various lubrication parts; Lubrication areas include: connections between moving parts, bearing installations, contact points between sliding parts, contact points between cams and followers, and seal installations.

3. The intelligent grease supply monitoring system according to claim 2, characterized in that: The specific implementation process of the data acquisition module is as follows: The factory area is divided into several supply zones, each of which is equipped with an intelligent oil injection pump and several mechanical equipment; For each supply area, parameter sensors are installed at each lubrication point of each mechanical equipment in the supply area to collect the operating parameters of each lubrication point; the parameter sensors include: temperature sensor, pressure sensor, vibration sensor, speed sensor, load sensor; the operating parameters include: temperature, pressure, vibration frequency, speed, and load.

4. The intelligent grease supply monitoring system according to claim 3, characterized in that: The specific process of the oil injection strategy generation module analyzing the oil injection amount of the lubrication part is as follows: When the mechanical equipment is started, the oil filling matching period is set, and the operating parameters of each lubrication part are obtained in real time. The average value of each operating parameter within the matching period is calculated to obtain the operating mean value; For each operating parameter, several operation mean intervals are preset, each operation mean interval corresponds to an operation extreme value, and the corresponding operation extreme value is output by matching the operation mean of each operating parameter with the corresponding interval; A weight coefficient is assigned to the extreme value corresponding to each operating parameter, and the oil injection evaluation value is obtained by multiplying all the operating parameters of the lubrication part by the corresponding weight coefficient and adding them together; Several oil injection evaluation value intervals are preset, each of which corresponds to a partial oil injection amount. By matching the oil injection evaluation value with all the oil injection evaluation value intervals, the corresponding partial oil injection amount Q is output.

5. The intelligent grease supply monitoring system according to claim 4, characterized in that: The specific process of the oil injection strategy generation module analyzing the injection frequency of the lubrication parts is as follows: For each lubrication part, the number of switching motion modes within the matching period is counted. The motion modes include: extension, contraction, rotation, and swing. The dynamic switching frequency value PZ is obtained by dividing the number of motion mode switching times by the matching period duration. Obtain the maximum load value and minimum load value of the lubrication part during the matching period, and obtain the load variation amplitude FZ by subtracting the minimum load value from the maximum load value; For each motion mode of the lubrication part, the maximum speed value and minimum amplitude value of the motion model within the matching period are obtained, and the dynamic change value is obtained by subtracting the two. Then, the dynamic change values of all the motion modes of the lubrication part are averaged to obtain the dynamic change mean value BZ; The injection frequency value ZP is obtained by combining the dynamic shear frequency value PZ, load change amplitude FZ, dynamic change mean BZ and oil injection amount Q corresponding to the lubrication part using the formula: ZP = (PZ×a1+FZ×a2+BZ×a3) / Q×a4, where a1, a2, and a3 are preset weight coefficients; Several injection frequency value intervals are preset, each injection frequency value interval corresponds to a partial injection frequency, and the corresponding partial injection frequency F is output by matching the injection frequency value with all injection frequency value intervals.

6. The intelligent grease supply monitoring system according to claim 5, characterized in that: The specific process of the oil injection strategy generation module analyzing the single oil injection amount and single injection frequency of the oil injection unit is as follows: For each oiling unit, the total oiling amount required for each lubricating part in the oiling unit is summarized and marked as Qi, i = 1, 2, ..., n; i is the number of the lubricating part, and n is the total number of lubricating parts; Obtain the length C and diameter R of the oil pipeline between the mechanical equipment corresponding to the oil injection unit and the intelligent oil injection pump in the corresponding supply area, as well as the oil injection error rate W of the intelligent oil injection pump. After normalization, use the formula: k = C × s1 + R × s2 + W × s3 to obtain the loss evaluation value k, where s1, s2, and s3 are preset weight coefficients. Preset multiple loss evaluation value intervals, each loss evaluation value interval corresponds to a loss rate, match the loss evaluation value with all loss evaluation value intervals, and output the corresponding loss rate q; Using the formula: Get the single oil injection amount QD, where wi is the preset weight coefficient corresponding to the oil injection amount of each part; Using the formula: Get the single bet frequency FD; For each oil injection unit, its corresponding single oil injection amount and single injection frequency are sent to the execution module. The execution module controls the intelligent oil injection pump to deliver grease according to the single injection frequency and single oil injection amount corresponding to the oil injection unit; then the oil injection unit injects grease into each lubrication part according to the corresponding partial oil injection amount and partial injection frequency of each lubrication part.

7. The intelligent grease supply monitoring system according to claim 6, characterized in that: The specific process of the oil injection control module analyzing the adjustment evaluation value and drawing a line graph of the adjustment evaluation value change is as follows: For each oiling unit, an oiling update cycle is set. Whenever the oiling update cycle is reached, the single oiling amount and single oiling frequency data corresponding to the oiling unit and the partial oiling amount and partial oiling frequency data corresponding to each lubrication part of the oiling unit are recalculated, and the oiling unit and lubrication parts are re-oiled based on the above data; For each update cycle, the duration corresponding to the update cycle is divided into several monitoring periods. For each lubrication part, the corresponding oil injection evaluation value and injection frequency value in each monitoring period are calculated, and weight coefficients are assigned to the oil injection evaluation value and injection frequency value respectively. Subsequently, the oil injection evaluation value and injection frequency value corresponding to the lubrication part in the monitoring period are multiplied by the corresponding weight coefficients and added together to obtain the adjustment evaluation value; A two-dimensional rectangular coordinate system is established, with the vertical axis being the adjustment evaluation value and the horizontal axis being time. The adjustment evaluation values corresponding to each monitoring period are substituted into the coordinate system in chronological order to obtain several data points. Adjacent data points in the coordinate system are then connected with line segments to obtain a broken line showing the change in the adjustment evaluation value.

8. The intelligent grease supply monitoring system according to claim 7, characterized in that: The specific process of analyzing and adjusting the judgment value of the oil injection control module is as follows: Starting from the initial moment of the update cycle, a sliding window is set in the adjustment value change line chart. The window size is a number of monitoring periods. After each new monitoring period ends, the monitoring period is included in the sliding window and the earliest monitoring period is removed. This process of adding and removing is defined as the update of the sliding window. When the sliding window is updated, the mean of the adjustment evaluation values corresponding to each monitoring period in the sliding window is calculated and recorded as the adjustment evaluation mean; According to the adjustment evaluation mean and the adjustment evaluation value corresponding to each monitoring period, the standard deviation calculation method is used to calculate and obtain the adjustment evaluation fluctuation value DP; By performing linear regression analysis on the adjustment evaluation value within the sliding window, the slope of the adjustment evaluation value changing over time is obtained, which is recorded as the adjustment evaluation trend value TQ; Extract the maximum and minimum adjustment evaluation values within the sliding window, and obtain the adjustment evaluation range value TC by subtracting the minimum adjustment evaluation value from the maximum adjustment evaluation value; After normalizing the adjustment evaluation fluctuation value DP, the adjustment evaluation trend value TQ and the adjustment evaluation range value TC, the adjustment evaluation judgment value TPZ is obtained using the formula: TPZ = DP×c1+TQ×c2+TC×c3; where c1, c2, and c3 are preset weight coefficients.

9. The intelligent grease supply monitoring system according to claim 8, characterized in that: The specific process of the oil injection control module determining whether to update the oil injection amount and injection frequency of the lubrication part is as follows: Preset the upper and lower thresholds SZ and XZ for adjusting the evaluation judgment, and compare the adjustment evaluation judgment value TPZ with the preset upper and lower thresholds for adjusting the evaluation judgment; If the adjustment evaluation judgment value is greater than the corresponding upper limit threshold, it is judged that the lubrication is excessive and the oil filling is updated using the formula: The reduced partial oil injection amount QJ and the reduced partial oil injection frequency FJ are obtained, where r1 is the reduction ratio of the partial oil injection amount; RQmax is the maximum allowable reduction ratio of the partial oil injection amount, Q is the original partial oil injection amount; r2 is the reduction ratio of the partial oil injection frequency, RFmax is the maximum allowable reduction ratio of the partial oil injection frequency, and F is the original partial oil injection frequency; By sending the reduced oil filling amount and reduced oil filling frequency corresponding to the lubrication part to the oil filling unit, an oil filling reduction instruction is generated at the same time. After receiving the instruction, the oil filling unit re-oils the lubrication part according to the reduced oil filling amount and reduced oil filling frequency corresponding to the lubrication part; If the adjustment evaluation value is less than the corresponding lower limit threshold, it is judged that the lubrication is insufficient and the oil filling is updated using the formula: Get the partial oil injection amount QG and the partial oil injection frequency FG, where h1 is the partial oil injection amount increase ratio; HQmax is the preset maximum allowable oil injection amount increase ratio, h2 is the partial oil injection frequency increase ratio, and HFmax is the preset maximum allowable oil injection frequency increase ratio; By sending the additional oil filling amount and additional oil filling frequency corresponding to the lubrication part to the oil filling unit, an oil filling increase instruction is generated at the same time. After receiving the instruction, the oil filling unit re-oils the lubrication part according to the additional oil filling amount and additional oil filling frequency FG corresponding to the lubrication part; If the adjustment evaluation judgment value is between the upper and lower threshold values, the lubrication is determined to be stable. At this time, the lubrication part continues to maintain the current oil filling amount and frequency for oil filling.

10. The intelligent grease supply monitoring system according to claim 9, characterized in that: The specific process of the oil injection control module recalculating the single oil injection amount and single injection frequency of the oil injection unit is as follows: For each oiling unit, if the corresponding partial oiling amount and partial oiling frequency of each lubrication part corresponding to the oiling unit are updated, the single oiling amount and single oiling frequency are recalculated according to the corresponding partial oiling amount and partial oiling frequency of each lubrication part after update, and the oiling update instruction of the oiling unit is generated and sent to the execution module. The execution module performs the oiling operation on the oiling unit according to the recalculated single oiling amount and single oiling frequency of the oiling unit.

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