Intelligent lubricating method for furnace roller bearing equipment

Abstract

The invention discloses an intelligent lubricating method for furnace roller bearing equipment, and belongs to the technical field of heating furnace lubrication in a heat treatment process. According to the core scheme, two double-line dry oil lubricating pumps are arranged in the middle of a furnace body and supply oil to an operation side bearing seat and a transmission side bearing seat respectively; each lubricating point is provided with a flowmeter with a feedback function and an electromagnetic on-off valve, and the flow is monitored in real time and the valves are controlled to be opened and closed through an industrial personal computer; and the pressure of the pipeline is maintained at 20MPa by using the electric pressure signal transmitter. The problems that a traditional lubricating system is uneven in oil supply, difficult in fault checking, out-of-control in oil feeding quantity and the like are solved, the bearing lubricating uniformity is improved by 60%, the fault checking time is shortened to 10 minutes, the oil feeding quantity deviation is controlled to be + / -5%, the service life of the bearing is remarkably prolonged, the steel plate defect rate is reduced, and the method is suitable for various long furnace body heat treatment devices.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of heating furnace lubrication equipment in heat treatment process, in particular to an intelligent lubrication design, manufacturing and using method of furnace roller bearing equipment, which is especially suitable for the lubrication system of the roller bearing of the steel plate heat treatment furnace under the long furnace body, multiple rollers and high temperature environment. BACKGROUND

[0002] In the production of steel plate heat treatment, the heat treatment furnace is one of the core equipment, which mainly processes container plate, high strength plate, wear-resistant plate, mechanical engineering die plate, ship and marine plate, high building and bridge plate, water and electricity plate, low alloy structural plate, etc., and is widely used in the fields of building, bridge, pressure vessel, offshore engineering, large steel structure, hydraulic engineering, etc.

[0003] At present, the lubrication mode of the furnace roller bearing seat of the heat treatment furnace generally adopts the traditional double-line centralized lubrication system, which has the following obvious defects: Uneven oil supply: due to the long furnace body (usually more than 30 meters) and the large number of furnace rollers (up to 50-100 groups) of the heat treatment furnace, the traditional single-pump oil supply system has the problem of large pipeline pressure loss, and the remote bearing seat is insufficient or lagged in oil supply, and some bearings even have the hidden danger of no lubricating grease, which leads to accelerated bearing wear.

[0004] Difficult to troubleshoot: there are many lubrication points (2-4 lubrication points for each furnace roller) and they are distributed dispersedly, when a lubrication point is blocked or has abnormal oil supply, it cannot be monitored in real time, and manual point-by-point troubleshooting is needed, which takes more than 4 hours on average, and easily leads to bearing damage due to lack of oil.

[0005] The oil supply cannot be accurately controlled: the traditional distributor is severely worn after long-term use, and the oil supply deviation can be more than ±30%. Insufficient oil supply will lead to insufficient lubrication of the bearing and shorten the service life by more than 50%; excessive oil supply will cause the lubricating grease to overflow, not only wasting (the annual waste of a single furnace can be more than 500 kg), but also causing the temperature to rise by 10-15℃ due to poor heat dissipation of the bearing seat, further accelerating the aging of the bearing, and generating hazardous waste disposal costs.

[0006] The above problems directly lead to the seizure and fracture of the furnace roller bearing, which changes the rolling contact into frictional contact during the conveying of the steel plate, resulting in quality defects such as scratches, bites and dents. According to statistics, the production line using the traditional lubrication system has a steel plate scrap rate of 3-5%, with an annual economic loss of more than one million yuan, and seriously affects the production rhythm and contract delivery, and restricts the development of new products. SUMMARY

[0007] The technical problem to be solved by the present application is to provide an intelligent lubrication method for the above-mentioned prior art, to realize precise and intelligent control of furnace roller bearing lubrication, to ensure production continuity and steel plate quality, and to solve the problems of uneven oil supply, difficult fault troubleshooting and inaccurate oil supply in the existing heat treatment furnace roller bearing lubrication system.

[0008] The technical scheme adopted by the present application to solve the above problems is an intelligent lubrication method for a furnace roller bearing device, which specifically includes the following contents: Double-pump partition oil supply system Two double-line dry oil lubrication pumps are arranged at the middle position of the heat treatment furnace body (within the range of ±5 meters from the midpoint in the furnace length direction), wherein the first lubrication pump supplies oil to all bearing seats of the operating side, and the second lubrication pump supplies oil to all bearing seats of the transmission side, and the total length of the pipeline of the first lubrication pump and the bearing seats of the operating side is not more than 20 meters, and the total length of the pipeline of the second lubrication pump and the bearing seats of the transmission side is not more than 20 meters.

[0009] The outlet pipeline of the lubrication pump adopts Φ16mm high-pressure seamless steel pipe, and the branch pipeline adopts Φ8mm high-pressure rubber pipe, so as to reduce the pressure loss along the pipeline.

[0010] Intelligent monitoring and feedback system A flowmeter with wireless feedback function (accuracy ±2%) is installed on the oil nozzle of each furnace roller bearing seat, and is numbered according to the rule of "furnace area - roller number - side", wherein the side is represented by "C" for the transmission side and "O" for the operating side. (such as "Z3-15-C" represents the transmission side of the 15th roller in the 3rd furnace area).

[0011] The flowmeter collects real-time lubricating grease flow data and sends it to the intelligent lubrication industrial computer in the operating room through an industrial wireless transmission module (transmission frequency 433MHz, delay ≤1s).

[0012] Precise oil control execution system An electromagnetic on-off valve (response time ≤0.5s, pressure resistance ≥30MPa) is connected in series downstream of each flowmeter, and the electromagnetic on-off valve is electrically connected with the flowmeter to receive the flow signal and execute the switching action.

[0013] The lubrication pump is provided with an electric pressure transmitter (measurement range 0-40MPa, accuracy ±0.5MPa), which maintains the dry oil pipeline pressure at 20MPa±1MPa through PID control, triggers the lubrication pump to supplement pressure when the pipeline pressure is lower than 19MPa, and stops oil supply when the pipeline pressure is higher than 21MPa.

[0014] Intelligent control logic The industrial control computer presets the theoretical grease amount for each bearing housing (based on the bearing model, speed, and temperature; for example, 0.8-1.2g of grease per hour for a 200mm diameter bearing).

[0015] When the flow meter detects that the actual grease supply reaches 95-105% of the theoretical value, it triggers the solenoid shut-off valve to close; when it is below 80% or above 120%, the industrial control computer issues an audible and visual alarm (alarm response time ≤3s) and displays the fault point number and abnormality type (insufficient / excessive) on the interface.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. Improved oil supply uniformity: Through dual-pump zoned oil supply and intermediate arrangement, pipeline pressure loss is reduced by more than 60%, and the oil supply time to the far-end bearing housing is shortened to less than 5 seconds, completely solving the problem of uneven oil supply.

[0017] 2. Improved fault response speed: The real-time monitoring and intelligent alarm system reduces the fault diagnosis time from 4 hours to less than 10 minutes, and reduces the bearing damage rate due to lack of lubrication by 90%.

[0018] 3. Precise and controllable oil supply: The electromagnetic on / off valve and flow meter are linked for control, and the oil supply deviation is controlled within ±5%. A single furnace can save more than 300 kg of lubricating grease per year, reduce the bearing housing temperature by 8-10℃, and extend the bearing service life by more than 100%.

[0019] 4. Improved production quality and efficiency: The smooth operation rate of furnace rollers has been increased to 99.9%, and the defect rate of steel plates such as scratches and dents has been reduced from 3-5% to below 0.1%, reducing economic losses by more than one million yuan per year, while ensuring stable production rhythm and smooth development of new products. Attached Figure Description

[0020] Figure 1 is a flowchart of the intelligent lubrication process, showing the entire process from lubrication pump oil supply to industrial control computer monitoring.

[0021] Figure 2 shows the implementation diagram of intelligent lubrication, where 2.1 is the dual-line dry oil lubrication pump on the operating side and 2.2 is the dual-line dry oil lubrication pump on the transmission side, both of which are arranged in the middle of the furnace body.

[0022] Figure 3 shows the implementation diagram of flow control at the lubrication point. 3.1 is the dual-line dry oil pipeline, 3.2 is the dry oil distributor, 3.3 is the solenoid on / off valve, 3.4 is the flow meter with feedback function, 3.5 is the terminal box, and 3.6 is the furnace roller bearing seat. Detailed Implementation

[0023] The technical solution of the present invention will be described in more detail below with reference to preferred embodiments. However, these embodiments are merely descriptions of preferred implementations of the present invention and should not be construed as limiting the scope of the present invention.

[0024] Equipment installation Two DRB-40 dual-line dry oil lubrication pumps are fixed on a steel structure support in the middle of the heat treatment furnace body, with a spacing of 1.5 meters. Pump 2.1 is connected to the operating side pipeline, and pump 2.2 is connected to the transmission side pipeline.

[0025] A LL-10 flow meter with feedback and a ZCT-15 solenoid on / off valve are installed sequentially at the oil nozzle of each furnace roller bearing seat. The flow meter collects signals through the terminal box (3.5) and then connects to the industrial control computer.

[0026] Parameter settings Input the theoretical grease application rate for each bearing housing into the industrial control computer (e.g., set the bearing model 22320 to 1.0 g / h), and set the upper pressure limit to 21 MPa and the lower pressure limit to 19 MPa.

[0027] Set alarm threshold: trigger an alarm when the actual flow rate is below 0.8g / h or above 1.2g / h.

[0028] Operation control Start the lubrication pump, and the electric pressure transmitter monitors the pipeline pressure in real time. When the pressure is lower than 19MPa, it automatically replenishes the pressure, and when it is higher than 21MPa, it stops supplying oil and maintains the pressure at 20MPa.

[0029] The flow meter collects flow data every 10 seconds. When the cumulative flow reaches the theoretical value (e.g., 1.0g), it sends a signal to the solenoid valve to close. The solenoid valve automatically opens at the start of the next oil supply cycle (set to 1 hour).

[0030] If the flow rate at a certain point exceeds the threshold three times consecutively, the industrial control computer screen will display the fault point number (such as "Z3-15-C") and simultaneously sound an alarm. Operators can quickly locate the fault point based on the number.

[0031] Maintenance Calibrate the flow meter monthly to ensure accuracy; check the solenoid on / off valve's operational flexibility quarterly; replace the high-pressure hose annually to prevent aging and leakage.

[0032] The above implementation methods can achieve intelligent and precise lubrication of heat treatment furnace roller bearings, effectively solve the defects of traditional lubrication systems, and significantly improve production efficiency.

[0033] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An intelligent lubrication method for furnace roller bearing equipment, characterized in that, Includes the following steps: Two dual-line dry oil lubrication pumps are installed in the middle of the heat treatment furnace body. The first lubrication pump supplies oil to all furnace roller bearing seats on the operating side, and the second lubrication pump supplies oil to all furnace roller bearing seats on the transmission side. A flow meter with feedback function is installed on the grease nozzle of each furnace roller bearing housing. The flow meter collects the grease flow data in real time and transmits it to the intelligent lubrication industrial control computer in the control room. Each of the flow meters is connected in series with an electromagnetic on / off valve downstream, and the electromagnetic on / off valve performs a switching action according to the flow signal of the flow meter; The lubrication pump is equipped with an electric pressure transmitter, which maintains the pressure of the dry oil pipeline at a preset value through pressure closed-loop control.

2. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that, The two dual-line dry oil lubrication pumps are arranged within ±5 meters of the midpoint of the furnace body along its length, and the total length of the pipeline between the first lubrication pump and the operating side bearing seat does not exceed 20 meters, and the total length of the pipeline between the second lubrication pump and the transmission side bearing seat does not exceed 20 meters.

3. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that: The flow meter uses a wireless transmission module to send flow data at a frequency of 433MHz, with a data transmission delay of ≤1s and a measurement accuracy of ±2%.

4. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that: The electromagnetic on / off valve has a response time of ≤0.5s, a pressure resistance of ≥30MPa, and is electrically connected to the flow meter. When the flow meter detects that the actual grease supply reaches 95-105% of the preset theoretical value, the electromagnetic on / off valve closes.

5. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that, The preset pressure value is 20MPa±1MPa. The electric pressure transmitter has a measurement range of 0-40MPa and an accuracy of ±0.5MPa. When the pipeline pressure is lower than 19MPa, the lubrication pump is triggered to replenish the pressure, and when it is higher than 21MPa, the oil supply is stopped.

6. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that: The intelligent lubrication industrial control computer presets the theoretical grease amount for each bearing housing. The theoretical grease amount is set according to the bearing model, speed and operating temperature. When the actual grease amount is lower than 80% or higher than 120% of the theoretical value, the industrial control computer issues an audible and visual alarm and displays the fault point number.

7. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that: The fault point numbering adopts the rule of "furnace area - roller number - side", where "C" represents the transmission side and "O" represents the operation side.

8. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that: The lubrication pump outlet pipeline uses Φ16mm high-pressure seamless steel pipe, and the branch pipeline uses Φ8mm high-pressure rubber hose. The oil supply cycle of the electromagnetic on / off valve can be set by the industrial control computer, with a setting range of 0.5-24 hours.

9. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that, Regular maintenance procedures include: monthly accuracy calibration of the flow meter, quarterly check of the solenoid on / off valve's operational flexibility, and annual replacement of the high-pressure hose.

10. The intelligent lubrication method for furnace roller bearing equipment according to claim 1, characterized in that, The intelligent lubrication industrial control computer has a data storage function, which can record historical flow data, pressure curves and fault information of each lubrication point, with a storage period of no less than 1 year.

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