Lubricating control system and control method of lubricating system

Abstract

The invention provides a lubrication control system and a control method of the lubrication system, and the lubrication control system comprises a gear flowmeter assembly, a lubrication oil station, a sensor assembly comprising a vibration sensor, a temperature sensor and a pressure sensor, and a fault diagnosis control unit in communication connection with all the assemblies. On-line fault diagnosis is executed by conducting correlation analysis on multi-source sensing signals, then the output flow of the lubricating oil station is dynamically adjusted, and on-demand lubrication based on the equipment state is achieved. According to the lubricating system, gear flowmeter monitoring and multi-sensor correlation analysis diagnosis are combined, a control closed loop is formed, on-demand lubricating based on the equipment state is achieved, the problem that the reliability of an existing lubricating system is insufficient due to the fact that the control dimension is single is solved, and the safety and reliability of equipment operation are improved.

Description

Technical Field

[0001] This application relates to the field of intelligent lubrication technology for fluid media, and in particular to a lubrication control system and a control method for the lubrication system. Background Technology

[0002] Lubrication systems are crucial for the normal operation of large mechanical equipment. Currently, common lubrication systems are mainly divided into constant flow lubrication systems and adaptive lubrication systems based on single parameter adjustment.

[0003] Constant flow lubrication systems provide lubrication by setting a fixed oil supply rate, resulting in a simple structure and low cost. However, in actual operation, the equipment load power constantly changes, and its demand for lubricating oil flow also changes accordingly. Constant flow systems cannot adjust according to actual operating conditions, easily leading to under-lubrication or over-lubrication, affecting equipment lifespan and causing energy waste.

[0004] Some adaptive lubrication systems can monitor and adjust the operating status of the lubrication system itself, but their diagnosis and adjustment are mainly limited to the operating parameters of the lubrication station itself (such as oil pump pressure and oil tank temperature).

[0005] Current lubrication systems mainly suffer from the following problems: constant flow systems cannot adapt to changing lubrication demands, posing a risk of insufficient or excessive lubrication; existing adaptive systems mostly rely on a single or a few operating parameters (such as temperature and pressure) for adjustment, and their control accuracy and reliability need to be improved; there is a lack of real-time monitoring and fault diagnosis capabilities for the mechanical operating status of lubricated equipment (such as bearings and gears), making predictive maintenance impossible; and the system's metering accuracy is easily affected by factors such as equipment aging and changes in oil characteristics, lacking a long-term stable accuracy assurance mechanism. Summary of the Invention

[0006] Based on this, the purpose of this application is to propose a lubrication control system and a control method for the lubrication system, so as to solve the problems of single control dimension and lack of predictive maintenance capability.

[0007] To achieve the above objectives, this application provides a lubrication control system, which includes: Gear flow meter assembly for monitoring lubricating oil flow; A lubrication station, connected to the gear flow meter assembly, is used to supply and circulate lubricating oil; Sensor components, including vibration sensors, temperature sensors, and pressure sensors; The fault diagnosis control unit is communicatively connected to the gear flow meter assembly, the lubrication station, and the sensor assembly; The fault diagnosis control unit is configured to: receive vibration signals from the vibration sensor, temperature signals from the temperature sensor, pressure signals from the pressure sensor, and flow signals from the gear flow meter assembly; perform correlation analysis on the vibration signals, temperature signals, pressure signals, and flow signals; perform online fault diagnosis based on the correlation analysis results; and output control commands to the lubricating oil station based on the fault diagnosis results to adjust the lubricating oil flow rate output by the lubricating oil station.

[0008] In one embodiment, the gear flow meter assembly includes a valve body and at least two sets of lubrication units located within the valve body, each of the lubrication units including a pair of meshing gears and a corresponding electrical pulse monitoring switch.

[0009] In one embodiment, the valve body is provided with a bypass valve and a throttle valve. The bypass valve is used to bypass the flow path during system maintenance, and the throttle valve is used to regulate the flow rate of the lubricating oil.

[0010] In one embodiment, the lubrication station includes an oil tank, a variable frequency motor, a lubrication pump, a dual filter, and a cooler. The inlet of the lubrication pump is connected to the oil tank, the variable frequency motor is driven by the lubrication pump, and the dual filter and the cooler are sequentially arranged on the outlet pipeline of the lubrication pump.

[0011] In one embodiment, the fault diagnosis control unit is configured to perform time-domain feature analysis on the vibration signal to diagnose the operating status of the mechanical component when performing fault diagnosis.

[0012] In one embodiment, the fault diagnosis control unit includes a multi-channel signal processing module, which includes a sensor interface, a communication interface, and a signal processing unit, supporting data interaction with an industrial IoT platform.

[0013] Based on the same inventive concept, this application also provides a control method for a lubrication system, using the lubrication control system described above, the method comprising: Acquire vibration, temperature, and pressure data of the lubrication system; Obtain flow data from the lubrication system; The vibration data, temperature data, pressure data, and flow rate data are correlated and analyzed. Based on the correlation analysis results, the fault diagnosis logic is executed to obtain the diagnosis results; Based on the diagnostic results, the supply of lubricating oil is dynamically adjusted.

[0014] In one embodiment, the fault diagnosis logic includes: The vibration data is subjected to time-domain feature analysis and correlated with the changes in the temperature data to diagnose the mechanical health status of the lubricated equipment.

[0015] In one embodiment, the method further includes: The gear flow meter assembly is periodically subjected to zero-point calibration and pulsating flow calibration, and the execution cycle can be dynamically configured according to the system operating status.

[0016] In one embodiment, dynamically adjusting the lubricant supply based on the diagnostic results includes: PID control technology is used to dynamically adjust control parameters based on changes in the viscosity and / or temperature of the lubricating oil in order to maintain a stable lubricating oil flow rate.

[0017] The lubrication control system provided in this application forms a closed-loop system with a gear flow meter assembly as the core monitoring unit, integrating a multi-parameter sensor array and control unit. This expands the control dimension of the lubrication system from maintaining its own operating parameters to monitoring and diagnosing the mechanical condition of the lubricated equipment. Through the coordinated analysis of flow, vibration, temperature, and pressure signals, it achieves on-demand lubrication based on the actual health status of the equipment, avoiding under-lubrication or over-lubrication. At the same time, it realizes the improvement of the lubrication system from timed and quantitative oil supply to predictive intelligent lubrication based on equipment condition, which helps to improve the reliability and safety of equipment operation. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in this application or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a lubrication control system according to an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a gear flow meter assembly in a lubrication control system according to an embodiment of this application; Figure 3 for Figure 2 A schematic diagram of the disassembled state of the gear flow meter assembly; Figure 4 This is a schematic diagram of the structure of the lubrication oil station in a lubrication control system according to an embodiment of this application; Figure 5 This is a schematic diagram of the structure of a fault diagnosis control unit in a lubrication control system according to an embodiment of this application; Figure 6This is a schematic flowchart illustrating a control method for a lubrication system according to another embodiment of this application.

[0020] Marker explanation: 100. Lubrication control system; 10. Gear flow meter assembly; 11. Valve body; 12. Bypass valve; 13. Mounting shaft; 14. Gear; 15. Throttling valve; 16. Electrical pulse monitoring switch; 17. Transparent observation window; 20. Lubrication oil station; 21. Oil tank; 22. Dual filter; 23. Variable frequency motor; 24. Lubrication pump; 25. Cooler; 26. Valve assembly; 30. Sensor assembly; 40. Fault diagnosis and control unit; 41. Multi-channel signal processing module. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0022] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this application should have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," and similar terms used in the embodiments of this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0023] The lubrication control system and lubrication system control method provided in this application will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments described herein are for the purpose of helping to understand the core concept of this application and are not intended to limit the scope of protection of this application.

[0024] The shortcomings of existing lubrication systems include: 1) Constant flow lubrication cannot adapt to load changes, leading to under-lubrication or over-lubrication; 2) Existing adaptive systems rely on a single parameter (such as temperature), resulting in insufficient control accuracy and reliability; 3) Lack of real-time monitoring and fault diagnosis capabilities for the mechanical condition of the lubricated equipment; and 4) The system's metering accuracy is easily affected by equipment aging and oil characteristics. Oil characteristics primarily refer to viscosity, which is temperature-dependent.

[0025] The embodiments of this application provide a solution for a lubrication control system, which achieves an improvement from passive oil supply to active lubrication and management by integrating a modular gear metering structure, a multi-physical quantity sensor array, and a control unit with online diagnostic and self-calibration functions.

[0026] Reference Figure 1 This application provides a lubrication control system 100, which includes a gear flow meter assembly 10, a lubrication oil station 20, a sensor assembly 30, and a fault diagnosis control unit 40. The gear flow meter assembly 10, the lubrication oil station 20, the sensor assembly 30, and the fault diagnosis control unit 40 form a monitoring and control closed loop.

[0027] Gear flow meter assembly 10 is used to monitor lubricating oil flow. Lubricating oil station 20 is connected to gear flow meter assembly 10 and is used to supply and circulate lubricating oil. Sensor assembly 30 includes a vibration sensor, a temperature sensor, and a pressure sensor. Fault diagnosis control unit 40 is communicatively connected to gear flow meter assembly 10, lubricating oil station 20, and sensor assembly 30.

[0028] The fault diagnosis control unit 40 is configured to: receive vibration signals from vibration sensors, temperature signals from temperature sensors, pressure signals from pressure sensors, and flow signals from gear flow meter assembly 10; perform correlation analysis on the vibration signals, temperature signals, pressure signals, and flow signals based on time-domain feature analysis and multi-parameter correlation determination; perform online fault diagnosis based on the correlation analysis results; and output control commands to lubrication station 20 according to the fault diagnosis results to adjust the lubrication oil flow rate output by lubrication station 20.

[0029] Specifically, the gear flow meter assembly 10 is connected to the oil outlet of the lubrication station 20 via a pipeline to monitor the flow rate of lubricating oil supplied to the lubricated equipment (such as bearings and gearboxes) in real time. The vibration sensor of the sensor assembly 30 is installed at the bearing housing of the lubricated equipment, while the temperature and pressure sensors are installed on the oil supply pipeline of the lubrication system. The fault diagnosis control unit 40 is connected to the gear flow meter assembly 10, the lubrication station 20, and the sensor assembly 30 via cables, forming a communication network. In this way, the lubrication control system 100 establishes a closed loop of "monitoring-diagnosis-control". By simultaneously incorporating four key physical quantities—flow rate, vibration, temperature, and pressure—into the diagnostic system, the monitoring dimensions of the traditional system are expanded, providing a hardware foundation for comprehensive equipment condition assessment.

[0030] The correlation analysis refers to the comprehensive calculation process by which the fault diagnosis control unit 40, after receiving the flow pulse signal from the gear flow meter assembly 10, the time-domain waveform signal from the vibration sensor, the temperature reading from the temperature sensor, and the pressure reading from the pressure sensor, performs synchronization, alignment, feature extraction, and correlation analysis on heterogeneous and asynchronous multi-source sensor information through embedded diagnostic logic. Specifically, the calculation process includes independent threshold judgment for each signal, as well as time-domain feature analysis of the vibration signal to extract characteristic parameters such as effective value, peak value, and kurtosis. These vibration characteristics are then correlated and collaboratively determined with multiple parameters, including temperature trends, pressure stability, and the deviation between the instantaneous flow rate and the setpoint. For example, the previously independent events of "abnormal increase in vibration amplitude" and "synchronous rise in bearing housing temperature" are fused and correlated to determine a composite fault mode of "severe bearing friction and wear," rather than a simple single-parameter over-limit alarm. This correlation analysis of multiple physical quantities provides a more reliable decision-making basis for subsequent adaptive lubrication control.

[0031] The lubrication control system 100 provided in this application, by forming a control system with a gear flow meter assembly as the core monitoring unit and integrating a multi-parameter sensor array and a fault diagnosis control unit, can upgrade a traditional lubrication system that only focuses on internal system parameters into an intelligent system capable of monitoring the mechanical state of the lubricated equipment and achieving on-demand lubrication. Through the coordination and correlation of multiple signals such as flow, vibration, temperature, and pressure, the system can not only maintain its own stable operation but also actively protect the health of the lubricated equipment, realizing a functional improvement from passive oil supply to active lubrication and health management, which helps to improve the operational reliability and safety of the entire equipment.

[0032] In some embodiments, the fault diagnosis control unit 40 is configured to perform time-domain feature analysis on the vibration signal to diagnose the operating state of the mechanical component when performing fault diagnosis.

[0033] For example, the signal processing unit inside the fault diagnosis control unit 40 performs time-domain feature analysis on the raw waveform signal from the vibration sensor and extracts feature parameters such as RMS value, peak value, and kurtosis. When the analysis finds that the RMS value of vibration continues to exceed the standard and the waveform kurtosis increases significantly, combined with the temperature signal, it is diagnosed as "early bearing wear fault".

[0034] Among them, the fault diagnosis control unit 40 elevates the diagnostic dimension from simple threshold judgment to signal feature analysis, which can identify early faults and potential risks that traditional methods cannot detect (such as gear backlash and bearing wear), and has predictive maintenance capabilities, avoiding the shortcomings of lacking real-time fault diagnosis and early warning intelligent functions.

[0035] Reference Figure 2In some embodiments, the gear flow meter assembly 10 includes a valve body 11 and at least two sets of lubrication units located within the valve body 11, each set of lubrication units including a pair of meshing gears 14 and a corresponding electrical pulse monitoring switch 16.

[0036] Furthermore, the valve body 11 is provided with a bypass valve 12 and a throttle valve 15. The bypass valve 12 is used to bypass the flow path during system maintenance, and the throttle valve 15 is used to regulate the flow rate of the lubricating oil.

[0037] For example, the valve body 11 of the gear flow meter assembly 10 has two completely independent lubrication unit cavities machined inside. Each lubrication unit contains a pair of meshing spur gears that rotate within a sealed cavity, driven by the pressure difference between the lubricating oil inlet and outlet. Lubricating oil from the supply line flows into the gear chamber from the valve body inlet, driving the gear pair to mesh and rotate, and then passes through the gear pair to the regulating valve at the outlet. The gear 14 is a spur gear, and an electrical pulse monitoring switch 16 is correspondingly mounted above the gear 14.

[0038] The valve body 11 integrates a bypass valve 12, a throttle valve 15 serving as a coarse regulating valve, and a fine regulating valve for precision adjustment. The coarse regulating valve is used to set the flow rate over a wide range, while the fine regulating valve performs precise fine adjustments within that range to achieve accurate control of the lubrication flow rate. If necessary, the bypass valve 12 can be used to cut off or open the flow meter assembly to control the amount of lubricating oil flowing through it.

[0039] A transparent observation window 17 is provided on the valve body 11. The transparent observation window 17 is made of resin glass plate and is used to observe the operation of the gear, so that on-site maintenance personnel can intuitively observe whether the gear operation is stuck or abnormal.

[0040] Each lubrication unit is equipped with an electrical pulse monitoring switch 16, which is mounted on the valve body 11 above a gear. It allows for both visual observation and electric monitoring, facilitating on-site observation and precise monitoring. The rotation of the gear is detected by the switch as a pulse signal, which is transmitted to the fault diagnosis control unit 40, where the pulse frequency is converted into an equivalent instantaneous lubricating oil flow rate.

[0041] The system employs a dual lubrication unit design, enabling redundant monitoring and flow distribution. Even if one lubrication unit fails, the system can still operate. Self-diagnosis is performed by comparing readings from both lubrication units, improving system reliability. The bypass valve 12 and throttle valve 15 are mounted on the valve body 11, resulting in a compact structure, reduced external piping connections, lower leakage risk and installation space requirements, and easier deployment in complex environments with long production lines.

[0042] This embodiment uses the example of setting two sets of lubrication units in the valve body for illustration. Those skilled in the art will understand that, depending on the requirements of flow monitoring and redundancy, more than two sets of lubrication units can also be set, and the basic principle is the same as that of this embodiment.

[0043] Furthermore, the modular design highly integrates multiple functions such as flow distribution, regulation, bypass maintenance, pulse metering, and visual monitoring onto a single valve block. By using various flow units to divide the oil flow in the main pipeline into specified flow rates, it is particularly suitable for multi-lubrication point operating conditions, achieving flow distribution and independent, precise control. The dual-unit structure not only provides redundancy but also allows for system cross-validation, further enhancing the reliability and accuracy of metering.

[0044] Reference Figure 3 In some embodiments, the lubrication station 20 includes an oil tank 21, a variable frequency motor 23, a lubrication pump 24, a dual filter 22, and a cooler 25. The inlet of the lubrication pump 24 is connected to the oil tank 21, the variable frequency motor 23 is driven by the lubrication pump 24, and the dual filter 22 and the cooler 25 are sequentially arranged on the outlet pipeline of the lubrication pump 24.

[0045] For example, the inlet of the lubrication pump 24 is connected to the oil tank 21 and is driven by an external variable frequency motor 23 via a coupling. The pumped lubricating oil first passes through a dual filter 22 for parallel redundant filtration, then enters the air-cooled cooler 25, and finally is supplied to the gear flow meter assembly 10 through a valve group.

[0046] The variable frequency motor 23 provides stepless speed regulation, laying the foundation for precise flow rate and dynamic adjustment. The dual filter 22 allows for filter element switching and maintenance without system shutdown, ensuring continuous oil supply. This ensures that the lubrication station 20 can provide stable, clean, and appropriately temperature-controlled lubricating oil under various operating conditions, providing hardware-level assurance for adaptive lubrication.

[0047] refer to Figure 5 In some embodiments, the fault diagnosis control unit 40 includes a multi-channel signal processing module 41, which includes a sensor interface, a communication interface, and a signal processing unit, and supports data interaction with an industrial Internet of Things platform.

[0048] Specifically, the multi-channel signal processing module 41 serves as the foundation of the fault diagnosis control unit 40. It can provide an analog input port to receive sensor signals, a digital input port to receive pulse signals from the gear flow meter, and upload diagnostic results, flow data, equipment health status and other information to the cloud IoT platform in real time through the built-in industrial Ethernet interface.

[0049] The multi-channel signal processing module 41 enables remote monitoring, data traceability, and centralized management. Maintenance personnel can receive early warning information via mobile phone or computer, promptly grasp the equipment status, reduce the intensity of on-site inspections and the risk of downtime, and improve production safety and intelligent management.

[0050] For example, the lubrication control system 100 employs a triple sensor architecture for signal acquisition: a gear flow meter assembly 10 with an accuracy of ±0.1 L / min; a vibration sensor, using a MEMS accelerometer, supporting high-frequency sampling at 20 kHz; and a temperature / pressure composite sensor with an accuracy of ±0.1 °C / ±0.1 bar.

[0051] The fault diagnosis logic includes time-domain feature analysis and temperature correlation for judgment. For example, the time-domain characteristics of vibration signals (such as amplitude and waveform) are analyzed and correlated with temperature change trends. If increased vibration is detected along with an abnormal temperature rise, it is judged as a risk of friction fault; if the vibration characteristics change but the temperature remains stable, it may be judged as mechanical loosening.

[0052] In addition, the lubrication control system 100 has the function of automatically performing zero-point calibration (±0.05%FS accuracy) periodically (e.g., every 24 hours) and pulsating flow calibration (0.1-10 L / min gradient test). Its calibration cycle can be dynamically adjusted (e.g., configurable from 1 to 720 hours), for example, when the system continuously monitors increased fluctuations in flow data or diagnoses potential fault risks, the calibration cycle can be automatically shortened.

[0053] By combining a multi-physical quantity sensor array with an online diagnostic logic module system, the system achieves an improvement from data acquisition to intelligent decision-making. The time-domain feature analysis and temperature correlation determination method enhances the diagnostic capability for early faults such as bearing wear and gear jamming. Combined with a high-precision automatic periodic calibration function, it effectively combats the attenuation of metering accuracy caused by mechanical wear and changes in oil properties.

[0054] In the lubrication control system 100, the lubrication station 20 supplies oil under the command of the fault diagnosis control unit 40. The oil drives the gears of the gear flow meter assembly 10 to rotate, and its pulse signals are monitored in real time. Simultaneously, vibration, temperature, and pressure signals are acquired by the sensor assembly 30. The control unit 40 performs correlation analysis on these signals and uses online diagnostic logic (including time-domain vibration and temperature correlation analysis) to determine the status of the system and equipment. Finally, based on the diagnostic results, it dynamically outputs commands to adjust the output of the lubrication station and periodically performs automatic calibration to maintain accuracy.

[0055] Based on the same inventive concept, embodiments of this application also provide a control method for a lubrication system, which is applied to the lubrication control system 100 of any of the foregoing embodiments.

[0056] refer to Figure 6 The control method for the lubrication system includes the following steps: Step S10: Obtain vibration data, temperature data, and pressure data of the lubrication system; Step S20: Obtain flow data of the lubrication system; Step S30: Perform correlation analysis on vibration data, temperature data, pressure data, and flow data; Step S40: Based on the correlation analysis results, execute the fault diagnosis logic to obtain the diagnosis results; Step S50: Based on the diagnostic results, dynamically adjust the supply of lubricating oil.

[0057] The lubrication system control method provided in this application establishes a process of synchronous acquisition of multi-sensor data, correlation analysis, intelligent fault diagnosis, and dynamic adjustment of lubricating oil quantity. It combines signal processing logic based on time-domain feature analysis with control theory in a lubrication control scenario, forming an executable, closed-loop intelligent decision-making logic. The correlation analysis includes determining the correlation between time-domain feature analysis and temperature changes. This ensures that the adjustment of lubricating oil supply is no longer based on a fixed setpoint or a single temperature feedback, but rather on diagnostic results that integrate multi-dimensional information such as equipment mechanical health status and system operating conditions, thereby achieving adaptive dynamic adjustment. This not only effectively avoids under-lubrication or over-lubrication, saving energy, but more importantly, it provides a stable and reliable methodological support for predictive maintenance of equipment.

[0058] In some embodiments, the fault diagnosis logic includes: Time-domain feature analysis is performed on vibration data, and correlation is established with temperature data changes to diagnose the mechanical health status of the lubricated equipment.

[0059] In some embodiments, the control method for the lubrication system further includes the following steps: Step S60: Periodically perform zero-point calibration and pulsating flow calibration on the gear flow meter assembly 10, and the execution cycle can be dynamically configured according to the system operating status.

[0060] In some embodiments, step S50 dynamically adjusts the supply of lubricating oil based on the diagnostic results, specifically including: PID control technology is used to dynamically adjust control parameters based on changes in the viscosity and / or temperature of the lubricating oil in order to maintain a stable lubricating oil flow rate.

[0061] The lubrication system control method integrates monitoring, decision-making, execution, and calibration. Through multi-parameter correlation analysis and diagnosis, the decision-making basis is more comprehensive; through adaptive PID and automatic calibration, the system can maintain high-precision flow control of ±0.5% over a long period of time, effectively addressing the accuracy degradation caused by changes in oil characteristics and equipment aging.

[0062] It should be noted that PID stands for "Proportional-Integral-Derivative," a classic feedback control algorithm in industrial control. Specifically, it calculates the "deviation" between a system's "setpoint" and "actual measured value," performs three different calculations (proportional, integral, and derivative) on this deviation, and then superimposes the results to generate a control signal that drives the actuator, ultimately enabling the system's actual output to quickly, smoothly, and accurately reach the setpoint.

[0063] In the lubrication control system 100 of this application, PID control is one of the core algorithms within the fault diagnosis control unit 40. The controlled object is the lubricating oil flow rate output by the lubrication oil station 20, the actuator is the variable frequency motor 23, and the feedback signal comes from the actual flow rate monitored by the gear flow meter assembly 10.

[0064] The workflow of PID control includes: the system sets a target flow rate, and the gear flow meter monitors the actual flow rate in real time; the PID algorithm calculates the deviation between the target and the actual flow rate and performs three operations: P (immediate adjustment), I (correction of cumulative error), and D (prediction of trend); a control command is output to the variable frequency motor; the variable frequency motor adjusts its speed and changes the output of the lubrication pump; ultimately, the actual flow rate accurately and stably follows the target flow rate.

[0065] For example, suppose the goal of the lubrication control system is to maintain a stable lubricating oil flow rate of 10 L / min. The three components of a PID controller play their roles in the lubrication control system in the following ways: The proportional (P) stage is used to control the "current" deviation, adjusting the control action immediately and proportionally based on the magnitude of the current flow deviation. If the current flow suddenly drops to 8 L / min (deviation of -2 L / min), the P stage will immediately calculate an adjustment, such as commanding the variable frequency motor to "immediately increase its speed slightly." The larger the deviation, the greater the adjustment.

[0066] The integral (I) is used to correct the "cumulative" deviation, considering the cumulative value of all deviations over a period of time (i.e., the integral of the deviation over time), with the aim of eliminating static errors. If, due to increased pipeline resistance, the system consistently exhibits a small, constant negative deviation, causing the flow rate to hover around 9.9 L / min for an extended period, the I-stage detects the continuous accumulation of this tiny deviation and outputs a "continuous, gradually increasing" command to slightly increase the speed of the variable frequency motor until the deviation is completely eliminated and the flow rate accurately returns to 10 L / min.

[0067] The differential (D) stage is used to predict future trends. It takes control measures in advance based on the rate of change of the current deviation (i.e., the derivative), enabling it to anticipate future changes in the deviation. If the flow rate drops rapidly from 10 L / min (e.g., to 9.5 L / min within 0.1 seconds), the D stage will detect the dangerous trend of "flow rate rapidly and uncontrollably decreasing." Instead of waiting for the deviation to become large, it immediately outputs a command to rapidly accelerate the variable frequency motor, effectively suppressing further flow rate declines and acting as a brake and damper.

[0068] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0069] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the inventive concept, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A lubrication control system, characterized in that, include: Gear flow meter assembly for monitoring lubricating oil flow; A lubrication station, connected to the gear flow meter assembly, is used to supply and circulate lubricating oil; Sensor components, including vibration sensors, temperature sensors, and pressure sensors; The fault diagnosis control unit is communicatively connected to the gear flow meter assembly, the lubrication station, and the sensor assembly; The fault diagnosis control unit is configured to: receive vibration signals from the vibration sensor, temperature signals from the temperature sensor, pressure signals from the pressure sensor, and flow signals from the gear flow meter assembly; and perform correlation analysis on the vibration signals, temperature signals, pressure signals, and flow signals. Online fault diagnosis is performed based on the correlation analysis results; based on the results of the fault diagnosis, control commands are output to the lubricating oil station to adjust the lubricating oil flow rate output by the lubricating oil station.

2. The lubrication control system according to claim 1, characterized in that, The gear flow meter assembly includes a valve body and at least two sets of lubrication units located within the valve body. Each lubrication unit includes a pair of meshing gears and a corresponding electrical pulse monitoring switch.

3. The lubrication control system according to claim 2, characterized in that, The valve body is equipped with a bypass valve and a throttle valve. The bypass valve is used to bypass the flow path during system maintenance, and the throttle valve is used to regulate the flow rate of the lubricating oil.

4. The lubrication control system according to claim 1, characterized in that, The lubrication station includes an oil tank, a variable frequency motor, a lubrication pump, a dual filter, and a cooler. The inlet of the lubrication pump is connected to the oil tank, the variable frequency motor is driven by the lubrication pump, and the dual filter and the cooler are sequentially arranged on the outlet pipeline of the lubrication pump.

5. The lubrication control system according to claim 1, characterized in that, The fault diagnosis control unit is configured to perform time-domain feature analysis on the vibration signal when performing fault diagnosis in order to diagnose the operating status of the mechanical components.

6. The lubrication control system according to claim 5, characterized in that, The fault diagnosis control unit includes a multi-channel signal processing module, which includes a sensor interface, a communication interface, and a signal processing unit, and supports data interaction with an industrial IoT platform.

7. A control method for a lubrication system, said method being applied to the lubrication control system according to any one of claims 1-6, characterized in that, The method includes: Acquire vibration, temperature, and pressure data of the lubrication system; Obtain flow data from the lubrication system; The vibration data, temperature data, pressure data, and flow rate data are correlated and analyzed. Based on the correlation analysis results, the fault diagnosis logic is executed to obtain the diagnosis results; Based on the diagnostic results, the supply of lubricating oil is dynamically adjusted.

8. The control method for the lubrication system according to claim 7, characterized in that, The fault diagnosis logic includes: The vibration data is subjected to time-domain feature analysis and correlated with the changes in the temperature data to diagnose the mechanical health status of the lubricated equipment.

9. The control method for the lubrication system according to claim 7, characterized in that, The method further includes: The gear flow meter assembly is periodically subjected to zero-point calibration and pulsating flow calibration, and the execution cycle can be dynamically configured according to the system operating status.

10. The control method for the lubrication system according to claim 7, characterized in that, The dynamic adjustment of the lubricant supply based on the diagnostic results includes: PID control technology is used to dynamically adjust control parameters based on changes in the viscosity and / or temperature of the lubricating oil in order to maintain a stable lubricating oil flow rate.

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