Motor bearing lubricating grease automatic quantitative oiling control system and control method

Abstract

The application relates to the technical field of industrial equipment lubrication maintenance, and discloses a motor bearing lubricating grease automatic quantitative oiling control system and a control method. The system comprises a dry oil pump, a high-pressure oil conveying hose connected to an oil outlet of the dry oil pump, a wireless remote control module, a handheld remote controller, a digital display timing and quantitative device and a self-sealing quick sealing joint. The wireless remote control module is connected to a control loop of the dry oil pump, and the wireless remote control module and the handheld remote controller are in wireless communication. The handheld remote controller is integrated with start-stop keys and an emergency stop key. The digital display timing and quantitative device is electrically connected to the wireless remote control module, the digital display timing and quantitative device is used for presetting a grease filling time length, and sends a stop signal to the wireless remote control module after timing ends. One end of the high-pressure oil conveying hose away from the dry oil pump is connected to the self-sealing quick sealing joint, and the self-sealing quick sealing joint is detachably sealed with a motor bearing oil inlet.

Description

Technical Field

[0001] This invention relates to the field of industrial equipment lubrication and maintenance technology, specifically to an automatic quantitative lubrication control system and method for motor bearings, which can be applied to the lubrication and filling operations of various industrial motor bearings in fields such as generator sets, chemical industry, and metallurgy. Background Technology

[0002] The generator set auxiliary system is equipped with multiple high-voltage and low-voltage motors. The motor bearings rely on lubricating grease to reduce friction, cool down the operation, and protect the components. The stability of bearing lubrication directly determines whether the generator set can operate continuously and safely.

[0003] Currently, the industry commonly uses a manual operation method involving a dry oil pump and threaded connectors to add lubricating grease. This method has several inherent drawbacks: First, the assembly and disassembly of the threaded connectors is cumbersome, resulting in low overall efficiency. Second, the distance between the dry oil pump and the lubrication point on the remote motor is relatively large, requiring multiple operators to coordinate, leading to high manpower input. Furthermore, the amount of grease added relies on manual judgment, resulting in poor accuracy and potential grease waste. Third, the work environment is generally harsh, characterized by high temperatures, oil buildup, and excessive noise. Fourth, the threaded connectors have poor sealing performance, making them prone to leaks and oil pipe detachment during use. Uncontrolled grease addition can also cause bearing overheating and wear, increasing equipment maintenance risks.

[0004] Existing industrial lubrication technologies are mainly divided into four categories: centralized lubrication systems, fixed metered lubrication devices, simple remote-controlled refueling equipment, and single-seal joints. Centralized lubrication systems require large-scale modifications to existing pipelines and equipment, resulting in high modification costs and long construction periods, and are unsuitable for on-site conditions where motors are distributed. Fixed metered lubrication devices only have local control functions and still require multiple personnel to operate them on-site. Simple remote-controlled refueling equipment only enables remote start-stop functions and lacks the ability for precise metered refueling and rapid emergency shutdown. Single-seal joints only optimize the sealing structure and do not change the traditional operating mode.

[0005] In summary, existing technologies cannot simultaneously achieve multiple functions such as low-cost retrofitting, remote control, precise quantitative filling, rapid connection, and emergency safety protection. Therefore, there is an urgent need to design a new type of automatic quantitative filling control system and control method for motor bearing lubricating grease. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies in motor bearing lubrication operations, such as low efficiency, high manpower consumption, poor lubrication accuracy, inadequate sealing effect, and high equipment maintenance risks. This invention provides an automatic quantitative lubrication control system and method for motor bearings. Without altering the original dry oil pump structure, this invention achieves remote control, precise quantitative lubrication, rapid connection, and emergency safety protection, effectively improving operational efficiency and equipment safety.

[0007] The technical solution adopted in this invention is: an automatic quantitative oil filling control system for motor bearing lubricating grease, including a dry oil pump and a high-pressure oil delivery hose connected to the oil outlet of the dry oil pump, and also including a wireless remote control module, a handheld remote control, a digital display timing and quantitative device and a self-sealing quick-sealing connector. The wireless remote control module is connected to the control circuit of the dry oil pump, and the wireless remote control module communicates wirelessly with the handheld remote control; the handheld remote control integrates a start / stop button and an emergency stop button; The digital display timing and metering device is electrically connected to the wireless remote control module. The digital display timing and metering device is used to preset the oil filling time and send a stop signal to the wireless remote control module after the timing ends. The end of the high-pressure oil hose away from the dry oil pump is connected to the self-sealing quick-sealing connector, which is detachably sealed to the motor bearing oil filler port.

[0008] The handheld remote control is a waterproof remote control; the effective communication distance between the handheld remote control and the wireless remote control module is not less than 150m; after the emergency stop button is triggered, the shutdown response time of the dry oil pump is less than 0.1s.

[0009] The self-sealing quick-sealing connector has a quick-plug self-locking structure, and is equipped with a self-sealing valve core and a sealing element inside; the pressure resistance of the self-sealing quick-sealing connector is not less than 30MPa.

[0010] The self-sealing quick-sealing connector is compatible with high-pressure oil hoses with an outer diameter of 8mm or 10mm; the maximum length of a single high-pressure oil hose is 50m; the digital display timing and dispensing device has a preset dispensing time of 120s for the SKF22318 motor bearing and a single grease dispensing volume of 200ml.

[0011] An automatic quantitative grease filling control method for motor bearings includes the following steps: S1. Equipment modification and parameter setting: Install a wireless remote control module on the control circuit of the dry oil pump, replace the original oil filling connector with a self-sealing quick-sealing connector, and set the oil filling time in the digital display timing and metering device according to the motor bearing model. S2. Connector locking: Connect the self-sealing quick-sealing connector to the motor bearing oil filler port to complete self-locking and sealing; S3. Remote start and lubrication: Operate the start / stop button on the handheld remote control to start the dry oil pump and add lubricating grease to the motor bearing; S4. Emergency Stop: In case of abnormal operating conditions during operation, operate the emergency stop button on the handheld remote control to control the dry oil pump to stop in an emergency. S5. Automatic shutdown: After the digital display timing and metering device completes the timing, the dry oil pump will be automatically stopped. S6. Disassembly and Finishing: Release the lock of the self-sealing quick-sealing joint and complete the disassembly, ending the lubrication operation for the bearings of a single motor.

[0012] Steps S2 to S6 are completed independently by a single person.

[0013] The lubrication operation time for a single motor bearing shall not exceed 4 minutes.

[0014] The beneficial effects of the present invention are as follows: The present invention has the following beneficial effects: This invention optimizes the operating mode and improves operating efficiency. It employs a remote control operation method, eliminating the need for multiple personnel to coordinate remotely; a single person can complete the entire refueling operation. Combined with a quick-connect sealing connector, it simplifies the operating process, effectively shortens the refueling time for a single machine, and significantly improves overall operating efficiency.

[0015] This invention offers high precision in grease filling, reducing grease loss. By setting the filling time using a digital display timing and metering device, it replaces traditional manual judgment of grease volume, achieving precise metering of grease. This avoids bearing failures caused by overfilling or underfilling, and significantly reduces unnecessary lubricant consumption.

[0016] This invention provides reliable sealing performance and eliminates leakage problems. The self-sealing quick-sealing connector combines a self-locking structure, a self-sealing valve core, and multiple sealing components to completely solve the problems of cumbersome disassembly and assembly, stripping, oil leakage, and oil pipe detachment of traditional threaded connectors, thereby improving the operational stability of equipment.

[0017] This invention boasts strong safety protection capabilities and efficient emergency response. The independently designed emergency stop button can shut down the equipment in a very short time, enabling a rapid response to sudden abnormal operating conditions and reducing equipment damage and on-site safety risks.

[0018] This invention is easy to modify and has a wide range of applications. It only requires modification to the dry oil pump control circuit and the refueling connector, without altering the main equipment or existing pipelines. The modification cost is low, installation is convenient, and it can be widely applied to various industrial motor bearing lubrication scenarios.

[0019] This invention improves working conditions and reduces labor intensity. The remote control mode shortens the operator's range of movement and reduces the time personnel spend in harsh environments with high temperatures and high oil pollution, effectively reducing labor intensity. Detailed Implementation

[0020] The present invention will be further described in detail below with reference to actual industrial application cases. Those skilled in the art can easily conceive of various equivalent modifications and variations within the technical scope disclosed in the present invention, and all such modifications and variations should be covered within the protection scope of the present invention.

[0021] Based on the existing dry oil pump and high-pressure oil delivery hose, this invention adds a wireless remote control module, a handheld remote control, a digital display timing and metering device, and a self-sealing quick-sealing connector.

[0022] The wireless remote control module is integrated into the existing control circuit of the dry oil pump (e.g., connected in parallel to the manual circuit breaker of the dry oil pump) without requiring modifications to the main structure of the dry oil pump. The wireless remote control module establishes a wireless communication connection with a handheld remote control, which integrates start / stop and emergency stop buttons, enabling remote start / stop and emergency shutdown of the dry oil pump in case of malfunction. The handheld remote control features a waterproof design, suitable for industrial environments with high dust and oil content. The effective communication distance between the handheld remote control and the wireless remote control module is no less than 150m, and the shutdown response time of the dry oil pump after triggering the emergency stop button is less than 0.1s.

[0023] The digital display timing and dispensing device is electrically connected to the wireless remote control module. Operators can preset the grease dispensing time within the device according to the usage requirements of different motor bearing models. When the timer expires, the device sends a stop signal to the wireless remote control module, controlling the dry grease pump to stop operating, thus achieving quantitative dispensing and automatic shutdown. For the SKF22318 motor bearing, the dispensing time can be preset to 120 seconds, corresponding to a single grease dispensing volume of 200 ml.

[0024] The high-pressure oil delivery hose uses the existing pipeline on site, and the maximum length of a single high-pressure oil delivery hose is set to 50m, which can adapt to the layout of the dispersed motors on site; the end of the high-pressure oil delivery hose away from the dry oil pump is connected to a self-sealing quick-sealing joint.

[0025] The self-sealing quick-locking connector adopts a quick-connect self-locking structure, with an internal self-sealing valve core and sealing element, and an overall pressure resistance of not less than 30MPa. This connector allows for quick insertion and automatic locking with the motor bearing oil filler port, and relies on the self-sealing valve core to achieve a leak-proof seal after oil supply stops. The self-sealing quick-locking connector is compatible with high-pressure oil hoses of 8mm or 10mm outer diameter, offering strong versatility.

[0026] The present invention also provides a refueling control method based on the above-mentioned control system, which specifically includes the following steps: S1. Equipment Modification and Parameter Setting: Install a wireless remote control module on the control circuit of the dry oil pump, and replace the original threaded oil filling connectors on site with self-sealing quick-sealing connectors; set the corresponding oil filling time in the digital display timing and metering device according to the model and specifications of the motor bearings.

[0027] S2. Connector locking: Connect the self-sealing quick-sealing connector to the motor bearing oil filler port to complete self-locking and sealing.

[0028] S3. Remote start and lubrication: Operate the start / stop button on the handheld remote control to start the dry oil pump and add lubricating grease to the inside of the motor bearing.

[0029] S4. Emergency Stop: If oil leakage, loose connections or other abnormal conditions occur during operation, operate the emergency stop button on the handheld remote control to control the dry oil pump to stop in an emergency. Operation can only continue after the fault has been eliminated.

[0030] S5. Automatic shutdown: After the digital display timing and metering device completes the preset time, it automatically controls the dry oil pump to stop running, thus completing the metered oil filling.

[0031] S6. Disassembly and finishing: Release the locking state of the self-sealing quick-sealing joint and complete the disassembly. After cleaning the oil stains on the interface, complete the lubrication operation of the bearing of a single motor.

[0032] The above operation process can be completed by a single person, and the time for a single complete oiling operation of a single motor bearing shall not exceed 4 minutes.

[0033] One example is a practical application case of a single high-voltage motor in the generator set's main control room. This case study demonstrates the field application of the high-voltage motor of the No. 1 induced draft fan of a 300,000 kW generator set. The motor is equipped with SKF22318 bearings and is a core auxiliary device of the generator set. The field environment has a year-round temperature of 40℃~45℃, high concentration of oil and dust, and a 50m oil pipeline.

[0034] On-site modification process: A wireless remote control module was added to the existing dry oil pump control circuit. The module's operating voltage was perfectly matched to the on-site dry oil pump. An IP67 waterproof handheld remote control was installed, with a measured effective communication distance of 150m between devices. After the emergency stop button was triggered, the dry oil pump's shutdown response time was 0.08s. All existing threaded oil filling connectors were replaced with self-sealing quick-sealing connectors. These connectors are compatible with 8mm outer diameter high-pressure oil hoses, have an overall pressure resistance of 30MPa, and integrate a spring self-locking mechanism and an oil-resistant self-sealing valve core. The digital display timer and metering device was preset with a filling time of 120s, corresponding to a single filling of 200ml of lubricating grease.

[0035] On-site operation procedure: The operator arrives at the motor refueling point with a handheld remote control, aligns the self-sealing quick-sealing connector with the refueling port and inserts it, and the connector automatically locks and seals; press the start / stop button on the remote control to start the dry oil pump, and the grease begins to be added; after 120 seconds of timing, the digital display timing and metering device automatically sends a stop signal, and the dry oil pump stops running; the operator unlocks and disconnects the connector and cleans the oil stains from the interface.

[0036] The entire single-machine operation lasted 3 minutes and 42 seconds, with all joints maintaining good seals and no leakage or detachment. The equipment has been running continuously for 6 months without any malfunctions in the joints, remote control module, or metering device. The filling volume has been stable, and there have been no issues with bearing temperature rise or excessive vibration due to abnormal lubrication.

[0037] One example is a case study of mass application of low-voltage motors in generator sets. This case study applies to all low-voltage auxiliary motors of Unit 1 of a 300,000 kW generator set, totaling 80 low-voltage motors. The motors are distributed in a decentralized manner, and the oil pipeline length of each unit is between 20m and 50m. The traditional operation mode requires 3 operators to work in groups to patrol and refuel, which makes personnel coordination difficult.

[0038] The system's batch modification scheme involves: uniformly installing wireless remote control modules on existing dry oil pumps, completely replacing all self-sealing quick-sealing connectors, and classifying and setting the refueling duration of the digital display timing and metering device according to different low-pressure motor bearing specifications. After the modification is completed, a single-person patrol operation mode is adopted, with operators sequentially refueling 80 low-pressure motors.

[0039] Actual on-site operation results: The average lubrication time for a single low-voltage motor is 3 minutes and 30 seconds, and a single person can complete the lubrication of 25 motors per day. Compared with the traditional mode, which requires a single person to handle 8 motors per day, the work efficiency is significantly improved. Due to the use of quick-connect sealing joints, the problems of stripped threads and oil leakage associated with traditional threaded joints are completely eliminated, reducing the daily average leakage failures in the on-site pipelines to zero. Based on the quantitative filling design, the grease filling error is controlled within ±2%, effectively avoiding problems such as insufficient or excessive grease in the low-voltage motor bearings. This batch application scenario has been running continuously for 4 months, with the entire system operating stably and adapting to the characteristics of dispersed motor layouts.

[0040] One example is a cross-scenario application case (desulfurization system equipment). This case study involves the application of the No. 2 circulating pump and induced draft fan motor in the desulfurization system of the generator set. It falls under the category of external expansion of the main engine room, with the equipment installed in an open location. Some pipelines use high-pressure oil hoses with an outer diameter of 10mm, and the environment is characterized by high humidity and high dust.

[0041] Equipment configuration adjustment: The self-sealing quick-sealing connector is selected to be compatible with the 10mm outer diameter high-pressure hose, and the single length of the high-pressure oil delivery hose remains at 50m; the structure and parameters of the handheld remote control, wireless remote control module, and digital display timing and metering device remain unchanged. Relying on the modular design, there is no need to modify the main structure of the dry oil pump, and only the connector needs to be replaced to complete the adaptation.

[0042] Practical Application: A total of 40 motors in the desulfurization system were modified. After completion, a single person can perform refueling operations throughout the entire system. In the high-humidity environment, the waterproof remote control did not experience button malfunctions or short circuits. Under conditions of long-term dust exposure, the self-sealing quick-sealing connector functioned normally in terms of insertion / removal, self-locking, and sealing, without any jamming or seal failure. This case demonstrates that the invention possesses universal adaptability across operating conditions and equipment types, and can be widely used in various types of auxiliary motors throughout the entire plant.

[0043] One example is a practical application case of emergency response to sudden abnormal working conditions on site. This case study is a practical application combining simulation and real-world sudden failures. A commonly used high-voltage motor in the generator set's main room was selected for testing to verify the system's emergency protection capabilities.

[0044] Test Scenario 1: Simulated refueling process with loose connectors and grease leakage. Upon discovering the leakage, the operator immediately pressed the emergency stop button on the handheld remote control. The dry grease pump stopped rapidly within 0.08 seconds, immediately interrupting grease delivery and preventing large-scale grease contamination or waste. After resolving the loose connector issue, operation could be resumed by reconnecting the connector. The entire emergency response process required no personnel to travel to the dry grease pump itself.

[0045] Test Scenario 2: During on-site operations, a slight sign of oil pipe detachment is detected. The operator visually detects the abnormality and immediately triggers the emergency stop function, instantly stopping the equipment and effectively preventing secondary problems such as large-scale oil leakage and equipment contamination caused by complete oil pipe detachment.

[0046] Compared to traditional operating methods, where traditional equipment lacks a remote emergency stop function, operators must walk 50 meters to shut down the dry oil pump, with the response time generally exceeding 10 seconds, making it impossible to quickly stop leaks. This invention, relying on an independent emergency stop button and a rapid response circuit, demonstrates extremely strong safety protection capabilities in actual on-site fault handling, effectively avoiding equipment damage and on-site safety hazards.

[0047] One example is a practical application case of long-term operational stability. A total of 120 modified generators from the generator set main room and desulfurization system were selected for a long-term tracking application for 8 months to comprehensively evaluate the system's durability, filling accuracy, and sealing reliability.

[0048] Summary of long-term operating data: Lubrication accuracy: The grease filling error of all equipment remained stable within ±2%, and the grease volume deviation problem common in manual filling did not occur; Sealing performance: The self-sealing quick-sealing joints of 120 devices have been inserted and removed tens of thousands of times without any stripping, leakage or detachment. Electrical control components: wireless remote control module, digital display timing and quantitative device, waterproof remote control. It operates around the clock and is minimally affected by high temperature, oil, and dust, with a zero electrical control failure rate. Equipment status: All modified motors no longer experienced abnormal bearing shutdowns or temperature exceedances caused by improper lubrication, and the continuity of equipment operation has been significantly improved.

[0049] This case demonstrates that the present invention has a robust overall structure and stable performance, enabling it to adapt to harsh industrial conditions for extended periods and meet the requirements for routine operation and maintenance of industrial equipment.

Claims

1. An automatic quantitative oiling control system for motor bearing lubricating grease, comprising a dry oil pump and a high-pressure oil delivery hose connected to the oil outlet of the dry oil pump, characterized in that: It also includes a wireless remote control module, a handheld remote control, a digital display timing and metering device, and a self-sealing quick-sealing connector; The wireless remote control module is connected to the control circuit of the dry oil pump, and the wireless remote control module communicates wirelessly with the handheld remote control; the handheld remote control integrates a start / stop button and an emergency stop button; The digital display timing and metering device is electrically connected to the wireless remote control module. The digital display timing and metering device is used to preset the oil filling time and send a stop signal to the wireless remote control module after the timing ends. The end of the high-pressure oil hose away from the dry oil pump is connected to the self-sealing quick-sealing connector, which is detachably sealed to the motor bearing oil filler port.

2. The automatic quantitative lubrication control system for motor bearings according to claim 1, characterized in that: The handheld remote control is a waterproof remote control; the effective communication distance between the handheld remote control and the wireless remote control module is not less than 150m; after the emergency stop button is triggered, the shutdown response time of the dry oil pump is less than 0.1s.

3. The automatic quantitative lubrication control system for motor bearings according to claim 1, characterized in that: The self-sealing quick-sealing connector has a quick-plug self-locking structure, and is equipped with a self-sealing valve core and a sealing element inside; the pressure resistance of the self-sealing quick-sealing connector is not less than 30MPa.

4. The automatic quantitative lubrication control system for motor bearings according to claim 1, characterized in that: The self-sealing quick-sealing connector is compatible with high-pressure oil hoses with an outer diameter of 8mm or 10mm; the maximum length of a single high-pressure oil hose is 50m; the digital display timing and dispensing device has a preset dispensing time of 120s for the SKF22318 motor bearing and a single grease dispensing volume of 200ml.

5. A method for automatically and quantitatively adding lubricating grease to motor bearings, characterized in that: The automatic quantitative lubrication control system for motor bearings according to any one of claims 1 to 4 includes the following steps: S1. Equipment modification and parameter setting: Install a wireless remote control module on the control circuit of the dry oil pump, replace the original oil filling connector with a self-sealing quick-sealing connector, and set the oil filling time in the digital display timing and metering device according to the motor bearing model. S2. Connector locking: Connect the self-sealing quick-sealing connector to the motor bearing oil filler port to complete self-locking and sealing; S3. Remote start and lubrication: Operate the start / stop button on the handheld remote control to start the dry oil pump and add lubricating grease to the motor bearing; S4. Emergency Stop: In case of abnormal operating conditions during operation, operate the emergency stop button on the handheld remote control to control the dry oil pump to stop in an emergency. S5. Automatic shutdown: After the digital display timing and metering device completes the timing, the dry oil pump will be automatically stopped. S6. Disassembly and Finishing: Release the lock of the self-sealing quick-sealing joint and complete the disassembly, ending the lubrication operation for the bearings of a single motor.

6. The automatic quantitative oiling control method for motor bearing lubricating grease according to claim 5, characterized in that: Steps S2 to S6 are completed independently by a single person.

7. The automatic quantitative oiling control method for motor bearing lubricating grease according to claim 5, characterized in that: The lubrication operation time for a single motor bearing shall not exceed 4 minutes.