A precision lubrication system for preventing jamming of a suspended trolley in an intelligent heat treatment production line.

Abstract

This application discloses a precision lubrication system for a suspended trolley used in an intelligent heat treatment production line to prevent jamming and address issues such as low lubrication precision caused by thermal deformation of the suspended trolley. The system comprises a central control unit, a power supply unit, a precision dispensing network, and a sensing spraying assembly. The control unit, based on a lubrication stepping algorithm and combined with position sensing signals, instructs a plunger pump to deliver a quantitative amount of lubricating oil to the dispensing network, which then acts on the friction pairs through atomizing nozzles. The system also integrates a jamming warning and emergency oil replenishment module. Through this solution, this application achieves efficient micro-volume lubrication, preventing the suspended chain from jamming and significantly reducing equipment maintenance costs and downtime risks.

Description

Technical Field

[0001] This invention belongs to the field of heat treatment equipment and its lubrication technology, specifically relating to a precision lubrication system for a suspended trolley used in an intelligent heat treatment production line to prevent jamming. Background Technology

[0002] In modern industrial automated production systems, heat treatment is a crucial step in enhancing the mechanical properties of metallic materials. The level of intelligence and operational stability of the production line directly determines the consistency of end-product quality and overall production efficiency. In the physical architecture of an intelligent heat treatment production line, the suspended trolley system, as a continuous conveying device undertaking the core function of material transfer, forms the cornerstone of the uninterrupted operation of the entire heat treatment process. Because the heat treatment process involves extremely high-temperature heating and subsequent cooling cycles, the suspended trolley and its associated catenary system must maintain long-term stable operation under extreme temperature fluctuations, high concentrations of dust particles, and complex mechanical loads.

[0003] In existing technologies, to maintain the flexibility of the suspension trolley's moving parts and extend their service life, regular lubrication of key friction components such as chain pins and sprockets is usually required. Early lubrication methods primarily relied on manual operation, where maintenance personnel would manually replenish lubrication points using oil guns or applicators when the equipment was stopped or running at low speeds. While this method is feasible in low-intensity operating environments, its drawbacks are becoming increasingly apparent in modern, high-paced intelligent production lines. On the one hand, the high-temperature environment inside and around the heat treatment furnace severely limits the frequency and precision of manual intervention, often resulting in significant "protective vacuum periods" in lubrication maintenance. On the other hand, manual lubrication, lacking quantitative monitoring methods, is prone to omissions, under-lubrication, or incorrect lubrication, preventing the formation of a stable and continuous fluid lubrication film at the friction interface, thus accelerating the wear process of mechanical components.

[0004] With the increasing level of industrial automation, several automated lubrication solutions have emerged to address the aforementioned problems. For example, in certain mechanical applications, precision lubrication systems based on electronic control units and sensors are used to achieve timed and quantitative lubrication replenishment by capturing the position signals of moving parts. This type of technology has shown some technological advancement in areas such as compressor cylinder lubrication or localized lubrication of die-casting molds, reducing lubricant waste and improving the targeting of lubrication through preset control logic. However, when these solutions are applied to the specific operating conditions of suspended heat treatment production lines, significant technical contradictions arise between their inherent design principles and the complex on-site environment.

[0005] Specifically, the suspended trolleys in the heat treatment production line are not in an ideal static physical state. Due to prolonged exposure to intense thermal cycling, the metal materials inevitably undergo creep and fatigue damage under continuous alternating thermal stress, causing minute but irreversible deformations in the physical structure of the suspended trolleys over time. This deformation directly disrupts the original design clearances between the suspended trolleys, as well as between the trolleys and the tracks and chains. When the structural deformation accumulates to a certain extent, the suspended trolleys may experience misalignment during operation. This abnormal stress distribution is transmitted through the complex multi-kinematic pair system, often becoming the cause of sudden chain jamming failures.

[0006] A more profound contradiction lies in the fact that existing lubrication technologies are mostly designed based on fixed lubrication points or single-trajectory motion models, lacking the ability to dynamically adapt to trajectory deviations caused by structural deformation. In environments with extreme high temperatures and dust coupling, the oxidation and drying rates of lubricants accelerate significantly. If fine dust enters friction pairs with varying gaps due to deformation, it forms high-hardness abrasive wear, further exacerbating the risk of jamming. Existing automatic lubrication systems often cannot simultaneously meet the synergistic lubrication needs of multiple moving parts, making it difficult to achieve full coverage and dynamic, precise compensation for critical stress points such as chain pins, sprockets, and suspension trolleys in complex motion sequences. This contradiction between the multidimensionality of lubrication needs under specific harsh conditions and the singularity of existing lubrication methods has become a key bottleneck restricting the fulfillment of production tasks in heat treatment production lines and leading to persistently high failure rates.

[0007] Therefore, designing a precision lubrication system that can effectively cope with component deformation, achieve multi-point collaborative control, and has high environmental adaptability, specifically for the unique physical environment and equipment operation characteristics of suspended heat treatment furnaces, in order to fundamentally solve the problem of suspension chain jamming and reduce operation and maintenance costs, has become a highly challenging and urgent key technical issue facing those skilled in the art. Summary of the Invention

[0008] This invention aims to address the technical shortcomings of existing heat treatment production lines, such as improper trolley engagement, frequent chain jamming, low precision of manual lubrication, and high equipment maintenance costs caused by thermal deformation of the physical structure of the suspended trolley due to high temperature, dust, and high load environments. To achieve the above-mentioned objectives, this invention provides an intelligent anti-jamming and precision lubrication system for suspended trolleys in heat treatment production lines.

[0009] This invention provides a precision lubrication system for preventing jamming of a suspended trolley in an intelligent heat treatment production line. The system comprises a central control and command unit, a power supply unit, a multi-channel precision distribution network, and an end-effector sensing and spraying component. The central control and command unit is electrically connected to the power supply unit and the end-effector sensing and spraying component. Based on a preset logical sequence and real-time feedback of physical state signals, it instructs the power supply unit to deliver a fixed amount of lubricating medium to the multi-channel precision distribution network, which ultimately acts on the key friction pairs of the suspended trolley through the end-effector sensing and spraying component.

[0010] The central control and command unit includes an industrial-grade programmable logic controller (PLC), a storage module, a human-machine interface, and a signal conditioning module. The PLC employs a microprocessor with multi-channel high-speed pulse input / output capabilities, and its core control logic is pre-loaded with a lubrication stepping algorithm based on accumulated operating load and ambient temperature compensation. The storage module dynamically records the passing frequency, single lubrication execution cycle, and system pressure fluctuation curve for each group of suspended trolleys. The signal conditioning module filters and performs level conversion on the weak electrical signals from the sensing spraying components at the execution end, ensuring the accuracy of logical judgments.

[0011] The power supply unit includes a lubricant storage tank, a high-pressure plunger pump assembly, a main oil supply pipeline, and a pressure monitoring component. The lubricant storage tank is equipped with an ultrasonic level detector to monitor the remaining lubricant volume in real time; it also has a top-mounted oil inlet with a breather valve to ensure constant pressure within the tank. The high-pressure plunger pump assembly is driven by an explosion-proof three-phase asynchronous motor and connected to the plunger pump body via a coupling. The output pressure generated by the plunger pump body is constant between 15MPa and 20MPa. The main oil supply pipeline uses seamless stainless steel pressure-resistant tubing, externally covered with a 20mm thick aluminum silicate fiber insulation layer to maintain the fluid viscosity stability of the lubricating medium in high-temperature workshop environments. The pressure monitoring component includes a pressure transmitter and a safety relief valve installed at the plunger pump outlet. The pressure transmitter uploads the pressure value to the central control unit in real time. When the system pressure exceeds 25MPa, the safety relief valve forces the lubricant back to the storage tank to prevent pipeline rupture.

[0012] The multi-channel precision dispensing network is located between the main oil supply line and each actuator, and its core component is a volumetric oil distributor. The volumetric oil distributor contains multiple independent metering chambers, each equipped with an adjustable piston mechanism. By adjusting the piston stroke, the precise amount of oil injected per cycle can be defined, with the adjustable range between 0.05ml and 0.5ml. The multi-channel precision dispensing network is connected to different lubrication points via branch hoses. These branch hoses are high-temperature resistant flexible conduits with an inner layer of polytetrafluoroethylene and an outer layer of stainless steel wire mesh to accommodate the slight vibrations during the operation of the suspension trolley.

[0013] The end-effector sensing spraying assembly includes a position sensing module, a spraying bracket, and a precision atomizing nozzle. The position sensing module employs a high-temperature resistant non-contact sensor, installed on a key node on the side of the suspended trolley's running track. The sensor identifies the position of the trolley's active pin and sends a trigger pulse signal to the central control unit. The precision atomizing nozzle is fixed to the inside of the track by the spraying bracket, and its nozzle contains a one-way anti-drip valve and a swirling atomizing plate. The opening pressure of the one-way anti-drip valve is set to 1.2 MPa to ensure no oil droplet leakage during non-lubrication periods. The swirling atomizing plate cuts the high-pressure fluid into particles with an average diameter of 30 μm to 50 μm, allowing the lubricating oil to penetrate the tiny gaps between the chain pins and sprockets, achieving full-coverage lubrication.

[0014] Furthermore, as a preferred embodiment of the present invention, the lubrication stepping algorithm built into the central control command unit follows the following mathematical logic: single lubrication interval time T int Based on the basic operating cycle T base The temperature correction factor α and the load correction factor β are jointly determined, and the calculation formula is T. int =T base *[1-α(T env -T ref )-β(P load / P std )], where T env To obtain the ambient temperature in real time via a PT100 temperature sensor installed near the track, T ref The reference temperature is set to 25°C; P load The real-time suspension load of the trolley is measured by a strain gauge pressure sensor mounted on the track support beam, P. std This is the rated standard load.

[0015] The range of values ​​for the temperature correction factor α and the load correction factor β, and their determination methods, are as follows:

[0016] Temperature correction factor α

[0017] Value range: 0.003~0.008, preferably 0.004~0.006.

[0018] Determination Method: The value was determined based on the high-temperature oxidation test curves of different lubricating oil models. Under standard test conditions of 25℃ to 120℃, the oxidation induction period, viscosity change rate, and oil film failure rate of the target lubricating medium were tested as a function of temperature. The influence coefficient of a unit temperature rise on the decline in lubrication performance was calculated based on the oil film evaporation loss rate and the temperature gradient corresponding to the doubling of the oxidation rate, thus determining the value of α. For high-temperature synthetic lubricating oils (temperature resistance ≥180℃), the value was 0.003 to 0.005; for ordinary mineral-based high-temperature lubricating oils, the value was 0.006 to 0.008.

[0019] Loading correction factor β

[0020] Value range: 0.10~0.25, preferably 0.12~0.20.

[0021] Method: Calibration based on suspension trolley load wear test. Under rated load Pstd, 1.2 times overload, and 1.5 times overload conditions, the wear amount and friction coefficient change curves of the pin and sprocket friction pair were tested to establish the load ratio (P load / P std The relationship between β and the lubricating film damage acceleration rate is calculated based on the proportion that the lubrication interval needs to be shortened for every 10% increase in load, and the value of β is determined accordingly. For light load conditions, the value is 0.10–0.15; for heavy load / full load conditions, the value is 0.18–0.25; and for conditions with frequent variable loads, the value is 0.15–0.20.

[0022] Collaborative calibration rules

[0023] Before the system is put into operation, the initial values ​​are preset according to the lubricating medium type and rated load. After 72 hours of continuous operation, the temperature, load, wear and lubrication response data recorded by the storage module are extracted. With the optimization goal of complete lubricating film, no dripping and no signs of jamming, α and β are calibrated in a closed loop to form a fixed parameter package adapted to this production line.

[0024] This algorithm allows the system to dynamically shorten the oil injection interval based on the rate of lubricant oxidation caused by ambient temperature rise and the increased friction loss caused by increased load, ensuring that an effective oil film always exists at the friction interface.

[0025] Furthermore, in a preferred embodiment of the present invention, the spraying bracket of the end-effector sensing spraying assembly has a three-dimensional degree-of-freedom adjustment mechanism. The three-dimensional degree-of-freedom adjustment mechanism consists of a base, a vertical adjustment screw, a horizontal adjustment slider, and a spherical rotary joint. Considering that long-term heat deformation of the suspended trolley may cause its pin centerline to deviate from its original theoretical trajectory, the operator can adjust the jet centerline of the precision atomizing nozzle to a tangential angle of 15° to 30° with the actual motion trajectory using the spherical rotary joint. This tangential jet design utilizes the negative pressure of the airflow generated by the sprocket rotation to adsorb oil mist and allow it to penetrate deep into the pin.

[0026] Furthermore, as a preferred embodiment of the present invention, the system also integrates a jamming warning and emergency oil replenishment module. This module monitors the drive current curve in real time by connecting the inverter current signal of the catenary drive motor to the central control unit. When the drive current is detected to rise instantaneously by more than 25% of the rated value within 0.5 seconds, the system determines that the suspension trolleys are jammed (i.e., a precursor to jamming). At this time, the central control unit immediately interrupts the regular lubrication program and activates the "high-frequency pulse flushing" mode. In this mode, the high-pressure plunger pump operates at the highest frequency, and through a multi-channel precision distribution network, it provides a continuous high-flow oil supply for 2 seconds to the three continuous nozzles around the obstruction point. The flow and impact force of the lubricant eliminate any possible abrasive particles or foreign objects and provide instantaneous friction reduction, thereby avoiding a complete line shutdown due to jamming.

[0027] Furthermore, in a preferred embodiment of the present invention, a magnetic sludge collection plate is provided at the bottom of the lubricant storage tank. The magnetic sludge collection plate is made of high-performance neodymium iron boron permanent magnet material and encapsulated in a stainless steel sealed shell. Since the dust in the heat treatment workshop contains a large number of metal oxide particles, magnetic adsorption can prevent tiny metal particles from entering the volumetric oil distributor with the lubricating oil, avoiding damage to the metering mechanism and ensuring the precision of the system's long-term operation.

[0028] Furthermore, in a preferred embodiment of the present invention, the outer layer of the electrical connection lines of the system is wrapped with flame-retardant braided mesh and aluminum alloy corrugated pipe. Along the cable path crossing the top of the high-temperature furnace area, a forced-air cooling sleeve driven by an air-cooled fan is added to maintain the cable operating environment temperature below 70°C, ensuring the real-time performance and stability of electrical signal transmission.

[0029] The present invention provides a precision lubrication system for preventing jamming of a suspended trolley in an intelligent heat treatment production line. Its working principle and execution process are as follows:

[0030] First, the system enters a self-test phase, where the central control unit detects the residual oil data returned by the ultrasonic level detector. If the liquid level is higher than the set minimum threshold, the system is allowed to start. When the suspended trolley of the intelligent heat treatment production line begins to move, the position sensing module senses the signal from the first trolley pin, and the central control unit receives the starting pulse, beginning to accumulate running time or running frequency.

[0031] Secondly, when the operating status meets the preset algorithm conditions, the central control and command unit activates the power supply unit. The high-pressure plunger pump draws in lubricant and pressurizes it to the preset pressure. The lubricant then enters the main oil supply line after passing through a precision filter with a filtration accuracy of 20μm. The pressure monitoring component feeds back the pressure to the controller, maintaining the system pressure at a constant 18MPa.

[0032] Next, the high-pressure oil enters a multi-channel precision distribution network. The volumetric oil distributor, based on the differentiated needs of each lubrication point (including chain pins, sprocket central shafts, suspension trolley pivots, etc.), quantitatively pushes the oil to each end-effector sensing spraying component. When the corresponding trolley pin passes approximately 5cm in front of the precision atomizing nozzle, the position sensing module provides a precise trigger signal. The central control unit then instructs the corresponding electromagnetic pilot valve to open, and the high-pressure lubricant is sprayed through the atomizing nozzle in a fan-shaped diffusion pattern onto the friction pair interface.

[0033] Finally, the system enters the closed-loop monitoring phase. Each distributor is equipped with a flow sensor; if no flow is detected within the predetermined execution cycle, the central control unit outputs a "pipeline blockage" alarm through the human-machine interface. Simultaneously, the system continuously monitors the drive motor current; if abnormal current fluctuations are detected, emergency oil replenishment logic is activated.

[0034] The beneficial effects of this invention are reflected in:

[0035] I. Through precise timing and metering control, the system achieves efficient micro-level replenishment of lubricating oil at key friction points. Compared to traditional manual lubrication, lubricant utilization is increased by more than 65%, completely eliminating direct metal-to-metal wear caused by insufficient lubrication and significantly slowing down the structural fatigue and deformation process of the suspension trolley.

[0036] Second, a solution combining position sensing and central control was adopted to solve the mechanical interference problem caused by trolley deformation under high-temperature conditions. The design of the multi-degree-of-freedom spraying bracket and precise atomized jet ensures that even when the trolley deviates from its trajectory by less than 3mm, the lubricating oil mist can still effectively cover the friction interface, fundamentally preventing the chain conveyor from jamming.

[0037] Third, the system's intelligent monitoring capabilities reduce maintenance frequency and labor intensity. The jamming warning and emergency flushing functions, achieved through drive current monitoring, enable the production line to self-heal in the face of sudden friction anomalies, reducing downtime.

[0038] Fourth, the system has been engineered and reinforced for high-temperature and dusty environments, such as insulated pipelines, breather valves, and magnetic sludge collection plates, to ensure the high reliability of the lubrication system under harsh industrial conditions and achieve comprehensive economic benefits of "reducing failures, reducing working hours, and saving costs".

[0039] As a detailed technical feature of this invention, a quick-change connector mechanism is provided between the precision atomizing nozzle and its connected branch hose. This quick-change connector mechanism consists of a self-sealing female connector and a male connector. When the nozzle becomes partially clogged due to dust accumulation and requires maintenance, offline replacement of the nozzle at a single point can be achieved without shutting down the main oil supply pump. The precision atomizing nozzle is also fitted with a protective cover made of high-temperature resistant asbestos cloth and metal mesh, which filters out most large dust particles, allowing only fine oil mist to pass through, thus extending the nozzle's service life.

[0040] The central control and command unit also has remote data communication capabilities, connecting to the factory's Manufacturing Execution System (MES) via an Ethernet interface. The system uploads maintenance status data for each set of suspension trolleys in real time. When the lubrication execution pressure of a certain set of trolleys remains excessively high, the MES system automatically generates a "potential deformation hazard" warning, reminding maintenance personnel to perform targeted corrections during production breaks, transforming reactive maintenance into predictive maintenance.

[0041] The lubricant storage tank of the power source supply unit is also equipped with an electrically heated thermostatic tube. In northern winters or during the cold start phase of the workshop, if the lubricant viscosity is too high, the thermostatic tube will automatically start to heat the oil temperature to 40°C, ensuring that the metering accuracy of the volumetric distributor is not compromised by viscosity fluctuations.

[0042] In summary, this invention, through systematic mechanical design, precise electronic sensing, and advanced algorithm compensation, constructs a complete precision lubrication system with environmental adaptability. This system not only solves the core technical pain point of preventing the suspended trolley from jamming in intelligent heat treatment production lines, but also boasts a compact structure, precise control, and low operating costs, making it highly valuable for industry promotion. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the overall structure of a precision lubrication system for an anti-jamming suspended trolley used in an intelligent heat treatment production line according to the present invention.

[0044] Figure 2 This is a schematic diagram of the power supply unit of the power source in this invention;

[0045] Figure 3 This is a schematic diagram of the volumetric oil distributor in the multi-channel precision dispensing network of the present invention;

[0046] Figure 4 This is a schematic diagram of the end-sensing spraying assembly and the three-dimensional degree-of-freedom adjustment mechanism in this invention;

[0047] Figure 5 This is the control system principle and logic block diagram of the present invention.

[0048] The attached diagram is labeled as follows: 1. Central control and command unit; 2. Power source power supply unit; 3. Multi-channel precision distribution network; 4. End-effector sensing spraying component; 5. Industrial-grade programmable logic controller; 6. Storage module; 7. Human-machine interface; 8. Signal conditioning module; 9. Lubricant storage tank; 10. High-pressure plunger pump assembly; 11. Main oil supply pipeline; 12. Pressure monitoring component; 13. Ultrasonic level detector; 14. Oil replenishment port; 15. Breather valve; 16. Explosion-proof three-phase asynchronous motor; 17. Coupling; 18. Plunger pump body; 19. Aluminum silicate fiber insulation layer; 20. Pressure transmitter; 21. Safety relief valve; 22. Volumetric oil distributor; 23. Piston mechanism; 24. Branch hose; 25. Position sensing module; 26. Spraying bracket; 27. Precision atomizing nozzle; 28. High-temperature resistant non-contact sensor; 29. ​​One-way anti-drip valve; 30. Swirl atomizing plate; 31. PT100 temperature sensor; 32. Strain gauge pressure sensor; 33. Three-dimensional freedom adjustment mechanism; 34. Base; 35. Vertical adjustment screw; 36. Horizontal adjustment slider; 37. Spherical rotary joint; 38. Magnetic sludge collection plate; 39. Flame-retardant braided mesh; 40. Aluminum alloy corrugated pipe; 41. Quick-change coupling mechanism; 42. Protective cover; 43. Electric heating thermostatic tube; 44. Suspension trolley; 45. Track. Detailed Implementation

[0049] To enable those skilled in the art to more clearly understand the technical solution of the present invention, the following description is provided in conjunction with the appendix. Figures 1 to 5 The present invention provides a detailed engineering description of a precision lubrication system for an intelligent heat treatment production line to prevent jamming of a suspended trolley, along with specific embodiments.

[0050] Figure 1This invention demonstrates the overall architecture of a precision lubrication system for an intelligent heat treatment production line to prevent trolley jamming. This system is not merely a mechanical lubrication device, but a closed-loop adaptive system integrating precision mechanics, electronic sensing, fluid dynamics calculations, and industrial control logic. Its core logic lies in addressing the extreme high temperatures, variable loads, and high dust conditions encountered in heat treatment workshops (such as carburizing, quenching, and tempering processes). Through dynamically sensed physical parameters, it adjusts the lubrication execution strategy in real time, thereby eliminating the trolley jamming phenomenon caused by excessive wear or thermal deformation of the friction pairs at its root.

[0051] Specifically, Figure 5 As shown, the central control and command unit 1, serving as the brain of the entire system, is physically installed in an electrical control cabinet with a protection level of no less than IP65, located beside the production line. The core component of the central control and command unit 1 is an industrial-grade programmable logic controller (PLC) 5. This controller utilizes a microprocessor with multi-channel high-speed pulse capture capabilities. It can not only process instantaneous pulses from the side position sensing module 25 of the track 45, but also accurately acquire analog signals from various parts of the production line through the integrated signal conditioning module 8. The signal conditioning module 8 contains multi-stage low-pass filters and electromagnetic shielding isolation circuits, effectively filtering out spatial electromagnetic interference generated by the high-power frequency converter and ensuring the fidelity of the microvolt-level voltage signals output by the PT100 temperature sensor 31 and the strain gauge pressure sensor 32 when converted to digital signals. The storage module 6 uses industrial-grade flash memory with redundant backup capabilities, which records in real-time the timestamps of each group of suspended trolleys 44, instantaneous ambient temperature, operating load, and the action response time of the end-sensing spraying component 4. The human-machine interface 7 provides a visual operating interface that allows process engineers to preset differentiated lubrication parameter packages according to different types of heat treatment products.

[0052] Furthermore, Figure 2As shown, the power supply unit 2, serving as the power source, elevates the lubricating medium to an extremely high potential energy state through the high-pressure plunger pump assembly 10. The lubricant storage tank 9 is typically made of 304 stainless steel, with a volume usually set between 50L and 100L depending on the scale of the entire production line. A liquid level ultrasonic detector 13 is installed on the top of the tank. This detector uses the principle of sound wave reflection to obtain the liquid level non-contactly and transmits a standard current signal of 4-20mA to the central control unit 1. When the liquid level is below the 20% warning threshold, the system automatically locks the oil replenishment pump or reminds the operator to replenish oil from the oil replenishment port 14 via the human-machine interface 7. The breather valve 15 on the tank contains a silica gel desiccant drying layer, which prevents the high humidity air from the heat treatment workshop from entering the tank and causing the lubricating oil to emulsify or accelerate oxidation. The high-pressure plunger pump assembly 10, driven by an explosion-proof three-phase asynchronous motor 16, is connected to the pump shaft via a quincunx flexible coupling 17. This connection method can compensate for minor axial misalignment caused by installation errors. The plunger pump body 18 is equipped with a ceramic piston, which can withstand high-pressure erosion of 15MPa to 20MPa for a long time without significant loss of geometric accuracy. To maintain the consistency of lubricating oil viscosity in different seasons and workshop locations, the main oil supply pipeline 11 is externally covered with an aluminum silicate fiber insulation layer 19 with a thickness of not less than 20mm, and a heat tracing cable is arranged inside the pipeline. The pressure transmitter 20 in the pressure monitoring component 12 converts the pump outlet pressure into an electrical signal and uploads it in real time. The safety relief valve 21 serves as a physical safety barrier, and its opening pressure is set at 25MPa. Once the system experiences pipeline blockage leading to an abnormal increase in pressure, the excess oil will be safely discharged to the storage tank 9 through the return oil pipeline.

[0053] The multi-channel precision distribution network 3 is the spatial link for achieving precise lubrication. Figure 3 As shown, in one specific embodiment of the invention, the network includes at least four sets of parallel-connected volumetric oil distributors 22. Each distributor's internal metering chamber employs an independently sealed design, and the piston's displacement stroke can be precisely changed by adjusting the rear limit bolt of the piston mechanism 23. For example, when lubricating the active pin of the suspension trolley 44, the displacement can be set to 0.2 ml, while for the secondary sprocket bearing, it can be set to 0.08 ml. The branch hose 24 adopts a multi-layer composite structure. The inner layer of high-density polytetrafluoroethylene material has excellent corrosion resistance and an extremely low internal wall friction coefficient, while the outer layer of stainless steel wire mesh provides the necessary mechanical tensile strength and wear resistance, preventing pipeline fatigue fracture caused by minor vibrations during frequent start-stop processes of the suspension trolley 44.

[0054] The end-effector sensing spraying component 4 is an actuator that directly acts on the friction interface. For example... Figure 4As shown, the high-temperature resistant non-contact sensor 28 in the position sensing module 25 typically employs the Hall effect principle or high-frequency eddy current principle, enabling it to accurately capture the wave peak signal passing through the pin shaft within a range of 10mm. The spraying bracket 26 is mounted inside the track 45 and integrates a three-dimensional degree-of-freedom adjustment mechanism 33. This mechanism achieves vertical alignment via a vertical adjustment screw 35, fine-tunes the lateral spacing via a horizontal adjustment slider 36, and provides the crucial rotational degree of freedom via a spherical rotary joint 37. In actual engineering debugging, installers will adjust the spray axis of the precision atomizing nozzle 27 to form a tangential angle of 20° with the center line of the pin shaft of the suspension trolley 44. This angle maximizes the utilization of the kinetic energy of the nozzle jet, guiding the oil mist around obstructions into the pin shaft gap. The precision atomizing nozzle 27 integrates a one-way anti-drip valve 29 with an adjustable preload spring plunger structure, allowing fluid to pass through only when the pipeline pressure exceeds 1.2 MPa, thus preventing oil dripping during non-lubrication stages from contaminating the heat-treated workpiece. The swirling atomizing plate 30 utilizes centrifugal force to cut the high-pressure oil into ultrafine droplets with a particle size distribution between 30 μm and 50 μm, forming a uniformly covered fan-shaped spray area.

[0055] Furthermore, a core technical advantage of this invention lies in the lubrication stepping algorithm operating within the central control and command unit 1. This algorithm no longer relies on simple timed triggering, but instead introduces ambient temperature compensation and load compensation. The single lubrication interval T... int The calculation formula is defined as T. int =T base *[1-α(T env -T ref )-β(P load / P std In a typical application embodiment, T base The interval is set to 3600 seconds, with α as a temperature correction factor of 0.005 and β as a load correction factor of 0.15. When the PT100 temperature sensor 31 near the heat treatment furnace detects that the ambient temperature has risen from the baseline 25°C to 80°C, the algorithm automatically shortens the lubrication interval to compensate for the evaporation loss and oxidation deterioration of the lubricating oil film at high temperatures. Simultaneously, when the strain gauge pressure sensor 32 indicates that the current suspension load exceeds the rated load, the system further increases the oil injection frequency to ensure that the friction pair is always in a full-film lubrication state, preventing metal seizing caused by boundary friction.

[0056] As a reliability enhancement design for extreme operating conditions, the system also integrates a jamming early warning and emergency lubrication module based on drive current monitoring. The central control command unit 1 is connected to the inverter communication port of the catenary motor via a shielded signal line. When the controller detects an abnormal surge in the derivative (i.e., rate of change) of the drive current, and the increase exceeds 25% of the rated current within 0.5 seconds, the system immediately executes the "emergency friction reduction logic". At this time, the high-pressure plunger pump assembly 10 rapidly increases the output pressure to 22MPa and instructs the three sets of end-sensing spraying assemblies 4 before and after the affected area to perform high-frequency pulse spraying. This high-intensity fluid impact can wash away the carbon deposits or metal shavings accumulated at the pin shaft, and reduce frictional resistance through the instantaneous intervention of a large amount of lubricant, thereby averting an impending mechanical jamming accident and preventing unexpected shutdown of the entire heat treatment line due to a single point of failure.

[0057] In terms of physical filtration, considering that oxide scale detached from the workpiece surface during heat treatment can easily mix into the lubrication path, a magnetic slag collection plate 38 is installed at the bottom of the lubricant storage tank 9 of the power supply unit 2 via countersunk screws. This collection plate is made of neodymium iron boron material with a magnetic energy product of not less than 40 MGOe, and the gradient magnetic field it generates can effectively capture ferromagnetic particles with a diameter as small as 5 μm, preventing them from entering the subsequent volumetric oil distributor 22. In addition, all electrical circuits of the system are wrapped in flame-retardant braided mesh 39 and run inside aluminum alloy corrugated pipes 40. When crossing extreme high-temperature areas such as the furnace top, the cable sheath temperature is controlled within a safe range by a forced cooling air sleeve driven by an air-cooled fan, ensuring the determinism of signal transmission.

[0058] To demonstrate the significant improvement of the technical solution of this invention compared to traditional lubrication solutions, this embodiment provides a set of comparative test data. The test environment was set on a carburizing and quenching production line in a large automotive parts factory. The production line is 280 meters long, has 150 sets of 44 suspended trolleys, operates at a speed of 0.15 m / s, and has a maximum workshop ambient temperature (furnace top area) of 95°C.

[0059] Example

[0060] This invention employs a precision lubrication system for preventing jamming of a suspended trolley in an intelligent heat treatment production line. The control algorithm parameters are set as follows: T base =1h, α=0.005, β=0.1, the jet tilt angle of the precision atomizing nozzle 27 is adjusted to 25°, and high-temperature synthetic chain oil is selected as the lubricating medium.

[0061] Comparative Example

[0062] It adopts a traditional timed and fixed-point automatic fuel injection system, which lacks environmental temperature compensation, load adaptation, and drive current monitoring functions. The fuel injection interval is fixed at once every hour, and the fuel injection quantity is controlled by the opening duration of a simple solenoid valve, lacking volumetric precision metering capabilities.

[0063] The experimental data collected after six consecutive months of production operation are shown in Table 1 below:

[0064] Table 1: Comparison of operational data between embodiments of the present invention and comparative examples:

[0065]

[0066] The quantitative experimental data clearly demonstrates that this invention significantly improves lubricant utilization through precise algorithm correction and engineered structural improvements. The comparative example's high oil consumption of 8.4L largely stemmed from "blindly adding oil" without dynamic adjustment based on operating conditions, resulting in excessive oil dripping or failing to penetrate deep into the friction pair. In contrast, the embodiment, through a micro-volume, high-efficiency spraying strategy, consumed only about one-third of the oil while achieving superior friction reduction. The significant decrease in pin wear strongly demonstrates the integrity of the lubricating oil film. The most significant engineering implication is the reduction of unplanned downtime from 12 times to 1 time, directly attributed to the system's drive current monitoring and emergency oil replenishment logic, eliminating most potential jamming hazards at their inception.

[0067] Furthermore, regarding system maintainability, a quick-connect coupling mechanism 41 is introduced between the precision atomizing nozzle 27 and the branch hose 24. This mechanism adopts a ball-locking self-sealing structure and has two matching one-way valves inside. When maintenance personnel find that a nozzle has become clogged due to prolonged contact with high-temperature oil fumes, there is no need to shut down the main pump of the power supply unit 2. Simply pull the locking sleeve of the quick-connect coupling backward to disconnect the pipeline under pressure, and the one-way valve will automatically close to prevent oil splashing. At this time, a spare cleaned nozzle can be quickly replaced. To deal with the suspended particles commonly found in heat treatment workshops, the protective cover 42 on the outside of the nozzle adopts a composite structure of multi-layer stainless steel microporous mesh and asbestos fiber layer. This design ensures that oil mist can pass through smoothly while blocking dust with a diameter greater than 100μm outside the nozzle outlet, extending the average cleaning cycle of the nozzle from the original 3 days to more than 20 days.

[0068] In applications targeting cold regions or winter cold starts, the electrically heated thermostatic tube 43 inside the power supply unit 2 plays a crucial role. The central control unit 1 monitors the oil temperature inside the tank via a built-in temperature comparator. When the oil temperature drops below 15°C (causing a sharp increase in viscosity, exceeding the normal operating range of the volumetric oil distributor 22), the thermostatic tube 43 automatically activates, maintaining the oil at a constant temperature of 40°C. This active temperature control technology ensures that regardless of changes in the external environment, the mass of lubricant pushed onto the friction pair by the system remains constant each time, eliminating lubrication errors caused by fluctuations in fluid dynamics.

[0069] The central control and command unit 1 also achieves data interaction with the factory's upper-level MES system through its built-in Ethernet physical layer interface using the Modbus TCP / IP protocol. The system not only uploads basic parameters such as operating pressure, liquid level, and temperature in real time, but also periodically pushes "equipment health diagnosis reports." Through in-depth analysis of historical operating current curves, the central controller can identify a trend of slow increase in the frictional resistance of a certain section of track 45 or a certain group of suspended trolleys 44. This trend analysis can help the factory's maintenance department accurately locate the trolley support with slight thermal deformation during downtime maintenance before a failure occurs, thus realizing the leap from "reactive maintenance" to "condition-predictive maintenance."

[0070] In another extended embodiment of the invention, for extra-large heat treatment lines with multiple parallel tracks, the multi-channel precision dispensing network 3 can be arranged in a distributed manner. Each track section is equipped with an independent volumetric distribution island, which communicates with the main control unit 5 via a bus-type control cable. This distributed architecture can effectively reduce pressure fluctuations and signal delays caused by long-distance pipelines and improve the synchronization of end-point response.

[0071] In summary, the intelligent heat treatment production line anti-jamming precision lubrication system for suspended trolleys of this invention is not a simple mechanical superposition, but rather achieves this through in-depth research into the frictional failure mechanism under heat treatment conditions. It utilizes sensor fusion technology to capture key physical quantities such as ambient temperature, motion load, position pulses, and drive current. Through scientific mathematical modeling and logic control, it achieves atomic-level precise control of minute amounts of lubricating medium under extreme environments. Its unique emergency protection mode and environmental compensation algorithm not only completely solve the technical pain point of suspended trolley jamming from an engineering perspective, but also demonstrate enormous industrial application potential in energy saving, consumption reduction, and improving equipment uptime. All structural dimensions, pressure settings, and control parameters disclosed in this invention are based on a large amount of first-hand engineering practice data, possessing strong feasibility and reproducibility.

[0072] For those skilled in the art, without departing from the above-described technical principles of this invention, equivalent non-substantial modifications can be made to the installation method of the spraying bracket 26 or the number of groups of the volumetric oil distributor 22 according to the specific production line layout. These modifications should all be considered to fall within the scope of protection of the claims of this invention. The selection of electrical components and general mechanical assembly processes not detailed in this embodiment can be performed in accordance with relevant national or industry standards. The ultimate engineering goal of this invention is to provide a highly reliable, maintenance-free, and data-traceable underlying support system for heat treatment automation in the context of intelligent manufacturing, thereby promoting the entire industry towards a green, efficient, and intelligent direction.

Claims

1. A precision lubrication system for a suspended trolley used in an intelligent heat treatment production line to prevent jamming, characterized in that, The system includes: The central control and command unit (1) is used to receive physical feedback signals including the position pulse of the suspended trolley, ambient temperature and track load, and output control commands according to the preset control logic. The power source power supply unit (2) is electrically connected to the central control and command unit (1) and is used to pressurize and transport the lubricating medium under the drive of the command, and to maintain the stability of the physical and chemical properties of the lubricating medium. A multi-channel precision distribution network (3), fluidly connected to the output end of the power supply unit (2), is used to quantitatively distribute the high-pressure conveyed lubricating medium as needed; and The execution end sensing spraying component (4) is electrically connected to the central control command unit (1) and fluidly connected to the multi-channel precision distribution network (3). The execution end sensing spraying component (4) is installed on the side of the track (45) on which the suspended trolley (44) runs. It is used to sense the real-time position of the suspended trolley (44) and accurately spray the lubricating medium in atomized form onto the friction pair interface of the suspended trolley (44).

2. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 1, characterized in that, The central control and command unit (1) includes an industrial-grade programmable logic controller (5), a storage module (6), a human-machine interface (7), and a signal conditioning module (8). The signal conditioning module (8) integrates a multi-level low-pass filter and an electromagnetic shielding isolation circuit to collect and process the ambient temperature signal from the PT100 temperature sensor (31) on the side of the track (45) and the load signal from the strain gauge pressure sensor (32) on the track support beam. The storage module (6) has a redundant backup function to dynamically record the passing frequency of the suspended trolley (44), the system operating pressure curve, and the execution cycle data of each lubrication point. The industrial-grade programmable logic controller (5) corrects the output pressure of the power source power supply unit (2) and the spraying sequence of the execution end sensing spraying component (4) in real time through a built-in adaptive algorithm based on the physical parameters input by the signal conditioning module (8) and the historical data in the storage module (6).

3. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 1, characterized in that, The power source power supply unit (2) includes: The lubricant storage tank (9) is equipped with a breather valve (15) with a silica gel drying layer and an oil replenishment port (14) on its top, and is equipped with an ultrasonic level detector (13) inside to monitor the oil level in a non-contact manner. The high-pressure plunger pump assembly (10) is driven by an explosion-proof three-phase asynchronous motor (16) through a plum blossom-shaped flexible coupling (17), and has a ceramic piston pump body (18) inside, which is used to generate a constant output pressure of 15MPa to 20MPa. The main oil supply line (11) is connected between the plunger pump body (18) and the multi-channel precision distribution network (3), and its outer periphery is covered with an aluminum silicate fiber insulation layer (19) with a thickness of not less than 20 mm; and The pressure monitoring component (12) includes a pressure transmitter (20) installed at the outlet of the plunger pump body (18) and a safety relief valve (21), the physical opening pressure of which is set to 25 MPa, for guiding the lubricating medium back to the lubricant storage tank (9) when the pipeline is blocked.

4. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 1, characterized in that, The multi-channel precision dispensing network (3) includes at least one set of parallel volumetric oil distributors (22). The volumetric oil distributor (22) has multiple independent metering chambers inside. Each metering chamber is equipped with a piston mechanism (23) with adjustable stroke. The rear end of the piston mechanism (23) is equipped with a limiting bolt for precisely defining the single dispensing volume, so that the single oil injection volume is adjustable in the range of 0.05ml to 0.5ml. The multi-channel precision dispensing network (3) is connected to the execution end sensing spraying assembly (4) through a branch hose (24). The branch hose (24) is a composite high-temperature resistant flexible conduit with a high-density polytetrafluoroethylene inner layer and a stainless steel wire braided mesh outer layer to counteract the mechanical vibration generated by the operation of the suspended trolley (44).

5. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 1, characterized in that, The execution end sensing spraying assembly (4) includes a position sensing module (25), a spraying bracket (26), and a precision atomizing nozzle (27). The position sensing module (25) uses a high-temperature resistant non-contact sensor (28) to capture the peak pulse signal when the pin shaft of the suspended trolley (44) passes through and feed it back to the central control command unit (1). The precision atomizing nozzle (27) integrates a one-way drip valve (29) with a pre-tightening spring plunger structure and a swirling atomizing plate (30). The opening pressure of the one-way drip valve (29) is 1.2 MPa. The swirling atomizing plate (30) uses centrifugal swirling to cut the lubricating medium into atomized particles with an average particle size of 30 μm to 50 μm.

6. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 2, characterized in that, In the adaptive algorithm executed by the industrial-grade programmable logic controller (5), the single lubrication interval time T int Logical calculations follow these rules: T int =T base *[1-α(T env -T ref )-β(P load / P std )]; Among them, T base T is the preset basic operating cycle. env T is the real-time ambient temperature fed back by the PT100 temperature sensor (31). ref P is the reference temperature of 25°C. load The real-time suspension load, P, is acquired by the strain gauge pressure sensor (32). std The rated standard load is defined as follows: α is a temperature correction factor reflecting the high-temperature oxidation rate of the lubricating medium, and β is a load correction factor reflecting the degree of load wear aggravation. The controller (5) has a built-in lookup table containing different operating condition parameters, based on the T value fed back by the signal conditioning module (8). env and P load The system retrieves matching dynamic values ​​of α and β in real time; and at preset intervals, it automatically verifies the integrity of the lubricating film by monitoring the pressure drop slope of the pressure divider, and adjusts the T accordingly. int Perform closed-loop fine-tuning within a range of ±5%.

7. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 5, characterized in that, The spraying bracket (26) integrates a three-dimensional degree-of-freedom adjustment mechanism (33), which consists of a base (34), a vertical adjustment screw (35), a horizontal adjustment slider (36), and a spherical rotary joint (37). Through the rotation adjustment of the spherical rotary joint (37), the precision atomizing nozzle (27) is set at the sprocket engagement point of the track (45). The mechanical biting pumping action generated at the moment of engagement between the sprocket and the chain is used to suck the tangentially sprayed particles into the pin gap. The nozzle (27) is equipped with a flow guide shroud, and the inner wall of the flow guide shroud is provided with a flow guide groove to concentrate the spray kinetic energy and forcibly compensate for the trajectory deviation caused by thermal deformation.

8. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 1, characterized in that, The system also integrates an emergency anti-jamming module based on drive current monitoring. The central control command unit (1) connects to the inverter current signal of the catenary drive motor and monitors the rate of change of drive current over time in real time. When the central control command unit (1) detects that the instantaneous rise of drive current within 0.5 seconds exceeds 25% of the rated current value, and when it is determined to be a sign of jamming, the controller commands the drive motor to perform a small amount of high-frequency forward and reverse rotation vibration. When the 22MPa high-pressure oil is used to force the friction pair by osmotic pressure when the mechanical gap is opened instantly, the ultrasonic transducer installed on the side of the nozzle applies cavitation vibration to the jamming point to accelerate the peeling of foreign matter and the penetration of lubricant.

9. The intelligent heat treatment production line anti-jamming precision lubrication system for a suspended trolley according to claim 3, characterized in that, In order to adapt to the high temperature and dusty environment of the heat treatment workshop, the bottom of the lubricant storage tank (9) is equipped with a magnetic slag collection plate (38) made of high performance neodymium iron boron permanent magnet material to capture ferromagnetic oxide particles with a diameter of not less than 5μm; the main oil supply pipeline (11) and the outer layer of the electrical circuit are wrapped with flame-retardant braided mesh (39) and aluminum alloy corrugated pipe (40), and a forced cooling air sleeve driven by an air-cooled fan is set on the cable path that crosses the furnace top area to ensure that the cable ambient temperature is kept constant below 70℃.

10. A precision lubrication system for preventing jamming of a suspended trolley in an intelligent heat treatment production line according to claim 5, characterized in that, The precision atomizing nozzle (27) and the branch hose (24) are connected by a self-sealing quick-change connector mechanism (41). The quick-change connector mechanism (41) is equipped with an interlocking one-way shut-off valve, which allows the nozzle to be replaced offline under pressure without shutting off the main oil supply pressure. The precision atomizing nozzle (27) is also fitted with a protective cover (42) made of multiple layers of stainless steel microporous mesh and asbestos fiber. The protective cover (42) includes a stainless steel mesh cover and a self-cleaning scraper set inside the mesh cover. The scraper is linked with the electromagnetic drive end of the nozzle (27). During the non-execution stage of spraying, the scraper reciprocates to scrape the inner wall of the microporous mesh, and the bottom of the protective cover (42) is provided with an opening to discharge the intercepted dust using the residual pressure during pulse spraying. The central control and command unit (1) connects to the factory MES system through an Ethernet physical interface and associates the lubrication execution status with the predictive maintenance logic.

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