Centralized bearing lubrication monitoring and control device

Abstract

In order to facilitate maintenance and reduce the maintenance cost of a lubrication system, the centralized bearing lubrication monitoring and control device comprises a bearing lubrication and monitoring system and an integrated control terminal. The bearing lubricating system comprises a bearing with a grease filling opening, a lubricating device and a controller, and the lubricating device comprises a pump, a distributor and the like and is provided with a resistance sensor. Data collected by a three-axis vibration temperature sensor of the monitoring system is transmitted to a terminal through a collector. The terminal comprises a data processing and storage unit, and a processing result is fed back to the controller to control the pump. The device can monitor in real time, solve maintenance problems, reduce cost, simplify installation, reduce maintenance difficulties and faults, and is reliable in data transmission.

Description

Technical Field

[0001] This utility model belongs to the field of bearing lubrication technology, specifically relating to a centralized bearing lubrication monitoring and control device. Background Technology

[0002] With the continuous innovation of power technology, the requirements for the quality and reliability of power generation equipment are constantly increasing. The monitoring and management of rotating machinery bearing systems are becoming increasingly sophisticated. However, the current means of supervising bearing lubrication are lacking. Although temperature and vibration monitoring equipment is occasionally used, it is mostly done offline on-site, requiring operation and maintenance personnel to record data one by one. The actual application effect is not good, resulting in the inability to detect grease loss, overheating, and rubbing in time, affecting the safe operation of critical rotating equipment. This leads to serious production accidents in the power industry, such as bearing grease loss, overheating, and rubbing.

[0003] Currently, bearing lubrication is mostly done manually using an oil gun or via offline automatic lubrication. However, both of these methods have certain drawbacks.

[0004] Manual grease filling method: Grease is filled periodically according to the equipment maintenance procedures. Unless an emergency defect occurs, grease filling is performed at the set time without any change. This means that if a sudden defect occurs, the grease may be significantly reduced, leading to equipment damage and production stoppage. Furthermore, the harsh working environment and confined space for some motors make grease filling difficult. In addition, inconsistent operator skill levels result in reduced filling accuracy, which is detrimental to long-term equipment operation and maintenance, and also leads to high labor costs.

[0005] Offline automatic grease filling: This type of equipment relies on external power supplies and uses an electric pump to fill grease according to a set cycle or filling method, failing to provide grease filling based on the user's condition. Furthermore, problems such as oil tank rupture can occur during operation. According to research, some power plants require the production team to perform air removal operations on the oil tank when replacing it, otherwise the oil tank is easily damaged. This significantly limits the use of offline automatic grease filling equipment.

[0006] With the increasing precision and automation of industrial equipment, the requirements for equipment maintenance are becoming more and more stringent. Therefore, real-time monitoring and lubrication of bearings, i.e., intelligent grease filling and maintenance based on bearing condition, is of great significance. Utility Model Content

[0007] The technical problem to be solved by this utility model is to provide an automatic lubrication control method and device for bearings that can determine different lubrication amounts according to equipment conditions, facilitate maintenance, and reduce the maintenance costs of the lubrication system.

[0008] To achieve the above objectives, the technical solution of this utility model is as follows: it includes a bearing, a lubrication device, and a controller. The bearing includes an inner ring, rolling elements, and an outer ring connected in sequence, with multiple grease fitting ports on the outer ring. The lubrication device includes a lubrication pump, a main pipeline, branch pipelines, and lubrication pipeline resistance sensors. The lubrication pump is connected to a distributor via the main pipeline, a first resistance sensor is installed on the main pipeline, and a second resistance sensor is installed on the branch pipeline.

[0009] Preferably, the control terminal includes a data processing unit and a data storage unit. The data processing unit is used to analyze and process the collected data; the data storage unit is used to store the collected data and the analysis and processing results; and the lubrication device control program unit is used to control the working status of the lubrication pump and distributor.

[0010] Includes the following steps:

[0011] Step 1: During the operation of the bearing equipment, operational data is collected, and the lubrication device performs a self-check. If the data collected by the lubrication pipeline resistance sensor is abnormal, the integrated control terminal will issue an early warning; if the data is normal, proceed to the next step.

[0012] Step 2: The control terminal analyzes the vibration signal data and temperature data of the bearing collected by the triaxial vibration temperature sensor to determine the amount of bearing grease to be replenished.

[0013] Step 3: The controller controls the lubrication pump and distributor to replenish grease. Once the grease level reaches the preset value, the lubrication device stops operating.

[0014] To further optimize this solution, in step 1, if the main pipeline resistance is higher than the set resistance and the branch pipeline resistance remains unchanged, then the main pipeline is blocked. If the main pipeline resistance is higher than the set resistance and some branch pipelines have normal resistance while others have no resistance change, then the distributor is blocked. If the main pipeline resistance is normal and some branch pipeline resistances are lower than the set value, then the branch pipeline is damaged and leaking grease. If the main pipeline resistance is normal and some branch pipeline resistances are higher than the normal value, then the branch pipeline is blocked.

[0015] To further optimize this solution, the bearing operation status monitoring system includes a triaxial vibration and temperature sensor. The triaxial vibration and temperature sensor is mounted on the bearing housing and is used to collect vibration signal data and temperature data from the bearing. The sensor wirelessly transmits the vibration signal data and temperature data to a field data collection device via a wireless network. This device can simultaneously collect real-time data from multiple triaxial vibration and temperature sensors. The data is then wirelessly transmitted to a control terminal. The control terminal's built-in data processing unit performs data simulation calculations on this real-time data. The calculated data is then transmitted to the controller, which controls the lubrication pump. The control terminal's built-in data storage unit stores the data transmitted by the sensors and the calculation results from the data processing unit, facilitating data retrieval from the control terminal.

[0016] To further optimize this solution, the lubrication monitoring system includes a triaxial vibration temperature sensor and a lubrication pipeline resistance acquisition unit. The triaxial vibration temperature sensor is used to collect vibration signal data and temperature data of the bearing, and the lubrication pipeline resistance acquisition unit is used to collect resistance data of the main pipeline and branch pipelines.

[0017] To further optimize this solution, the control terminal includes a data processing unit and a data storage unit. The data processing unit is used to analyze and process the collected data, while the data storage unit is used to store the collected data and the analysis and processing results.

[0018] To further optimize this solution, the communication connection between the triaxial vibration temperature sensor and the data collection device, as well as the connection between the collector and the integrated control terminal, utilizes a 2400M wireless module. The integrated terminal module has two 2400M-LORA wireless modules operating in slave mode, passively receiving data from the collector. Multiple collectors can be assigned to different terminal modules using their respective 2400M-LORA channels as needed.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] 1. Achieve comprehensive monitoring and precise control of the bearing lubrication system. Data is collected by various sensors, and the controller uses this data to control the lubrication pump and distributor to replenish grease, ensuring good bearing lubrication and extending bearing life. 2. The integrated control terminal is independently assembled, with the data processing and storage units built-in, ensuring reliable data processing and storage. It can also analyze, process, and predict various collected data, efficiently and reliably monitoring bearing operating status. 3. Utilize wireless communication for data transmission, avoiding wiring issues, simplifying installation, and ensuring reliable data transmission. For example, the wireless connection between the triaxial vibration temperature sensor and the collection device, as well as between the collector and the integrated control terminal, ensures stable information transmission. Attached Figure Description

[0021] Figure 1 is a schematic diagram of the structure of the centralized bearing lubrication monitoring and control device of this utility model.

[0022] Figure 2 is a flowchart of the centralized bearing lubrication monitoring and control device of this utility model.

[0023] The components include: 1. Bearing; 2. Lubrication device; 3. Controller; 4. Inner ring of bearing; 5. Rolling element of bearing; 6. Outer ring of bearing; 7. Grease port; 8. Lubrication pump; 9. Main pipeline; 10. Distributor; 11. Branch pipeline; 12. First resistance sensor; 13. Second resistance sensor; 14. Triaxial vibration temperature sensor. Detailed Implementation

[0024] The technical solution of this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0025] As shown in the attached drawings, the device includes a bearing 1, a lubrication device 2, and a controller 3. The bearing 1 includes an inner ring 4, rolling elements 5, and an outer ring 6 connected in sequence. The outer ring 6 has multiple grease inlets 7. The lubrication device 2 includes a lubrication pump 8, which is connected to a distributor 10 via a main pipeline 9. The distributor 10 is connected to the grease inlets 7 via a branch pipeline 11. A first resistance sensor 12 is provided on the main pipeline 9, and a second resistance sensor 13 is provided on the branch pipeline 11. The controller is communicatively connected to a triaxial vibration temperature sensor 14. The lubrication pump 8, distributor 10, first resistance sensor 12, and second resistance sensor 13 are all electrically connected to the controller 3.

[0026] When the equipment starts running, the intelligent bearing lubrication control device performs a system self-check and replenishes grease according to the set lubrication parameters. The first resistance sensor 12 and the second resistance sensor 13 collect resistance data of the corresponding pipelines at each grease inlet 7. When the resistance value of the lubrication pipeline is lower than the normal pipeline resistance range, the integrated control terminal issues a lubrication pipeline disconnection fault signal. When the resistance value of the lubrication pipeline is higher than the normal pipeline resistance range, the integrated control terminal issues a lubrication pipeline blockage fault signal, and the lubrication device stops working.

[0027] More specifically, the integrated control terminal includes a data processing unit and a data storage unit. The lubrication pump and distributor 10 are electrically connected to the controller 3. The triaxial vibration and temperature sensor 14 wirelessly transmits vibration signal data and temperature data to the data processing unit via a wireless network. The lubrication pipeline resistance acquisition sensors include a first resistance sensor 12 and a second resistance sensor 13. The first resistance sensor 12 is used to monitor whether the main pipeline 9 of the bearing intelligent lubrication system is normal, and the second resistance sensor 13 is used to monitor whether the branch pipeline 11 of the bearing intelligent lubrication system is normal. The triaxial vibration and temperature sensor 14 is used to acquire vibration signal data and temperature data of the bearing. The data processing unit is used to analyze and process the acquired data, and the data storage unit is used to store the acquired data and the analysis and processing results.

[0028] Step 1: During the operation of bearing 1, operating data is collected, and lubrication device 2 performs a self-check. If the data collected by the lubrication pipeline resistance acquisition sensors (including the first resistance sensor 12 and the second resistance sensor 13) is abnormal, the integrated control terminal will issue an early warning; if the data is normal, proceed to the next step.

[0029] Step 2: The control terminal (integrated control terminal) analyzes the vibration signal data and temperature data of bearing 1 collected by the triaxial vibration temperature sensor 14 to determine the amount of grease required to be added to bearing 1.

[0030] Step 3: Controller 3 controls the lubrication pump 8 and distributor 10 to replenish grease. Once the grease level reaches the preset value, the lubrication device 2 stops operating.

[0031] More specifically, in the steps, if the resistance value of the main pipe 9 is higher than the set resistance and the resistance of the branch pipe 11 does not change, then the main pipe 9 is blocked; if the resistance value of the main pipe 9 is higher than the set resistance and some branches of the branch pipe 11 have normal resistance while others have no resistance change, then the distributor 10 is blocked; if the resistance of the main pipe 9 is normal and the resistance of some branches is lower than the set value, then the branch pipe is damaged and leaking grease; if the resistance of the main pipe 9 is normal and the resistance of some branches is higher than the normal value, then the branch pipe is blocked.

[0032] More specifically, when the equipment starts running, the automatic lubrication device (lubrication device 2) performs a system self-check and replenishes grease according to the set lubrication parameters; when the resistance value of the lubrication pipeline is lower than the normal pipeline resistance range, the integrated control terminal sends a lubrication pipeline disconnection fault signal; when the resistance value of the lubrication pipeline is higher than the normal pipeline resistance range, the integrated control terminal sends a lubrication pipeline blockage fault signal, and the lubrication device 2 stops working.

[0033] More specifically, the data processing unit and data storage unit are integrated into an integrated control terminal, which is independently installed in the field environment to ensure the reliability of the data processing unit and data storage unit. By mounting the triaxial vibration temperature sensor 14 on the bearing housing, it is easy to collect vibration signal data and temperature data of the bearing 1. The lubrication pipeline resistance acquisition unit (including the first resistance sensor 12 and the second resistance sensor 13) is used to collect resistance data of the main pipeline 9 and the branch pipeline 11. The data is transmitted to the collector, which then transmits the data to the integrated control terminal. The data processing unit processes, analyzes, and predicts the vibration signal data, temperature data, and resistance data to monitor the operating status of the bearing 1. The data storage unit stores the collected data and the analysis and processing results. The integrated control terminal transmits the processing results to the controller 3 mounted on the lubrication pump 8. The controller 3 controls the operating status of the lubrication pump 8 and the distributor 10. This method, using wireless communication to forward vibration signal data, offers superior performance and enables more efficient and reliable monitoring of the bearing 1's operating status. Furthermore, this method eliminates the need to consider wiring issues, simplifying installation, and ensures highly reliable data transmission.

[0034] More specifically, the wireless transmission method between wireless communication devices: the communication connection between the triaxial vibration temperature sensor 14 and the collecting device, and between the collector and the integrated control terminal, uses a 2400M wireless module. The integrated terminal module has two 2400M-LORA wireless modules, operating in slave mode, passively receiving data from the collector. Multiple collectors can be assigned to different terminal modules' two 2400M-LORA channels as needed.

[0035] In summary, this document has used specific examples to illustrate the principles and implementation methods of this utility model. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this utility model. Furthermore, those skilled in the art will recognize that, based on the ideas of this utility model, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A centralized bearing lubrication monitoring and control apparatus, characterized by, The application relates to a bearing lubrication system, which comprises a bearing, a lubrication device and a controller, the bearing is sequentially connected with an inner ring, rolling bodies and an outer ring, the outer ring is provided with a plurality of grease supplementing openings; the lubrication device comprises a lubrication pump, the lubrication pump is connected with a distributor through a main pipeline, the distributor is connected with the grease supplementing openings through branch pipelines, the main pipeline is provided with a first resistance sensor, the branch pipelines are provided with second resistance sensors, the lubrication pump, the distributor, the first resistance sensor and the second resistance sensors are electrically connected with the controller; a bearing monitoring system, which comprises three-axis vibration temperature sensors arranged on a bearing seat of equipment, is used for collecting vibration signal data and temperature data of the bearing; a control terminal comprises a data processing unit and a data storage unit, the control terminal is in communication connection with the bearing monitoring system and is electrically connected with lubrication pipeline resistance acquisition sensors, the data processing unit is used for analyzing and processing the vibration signal data and the temperature data of the bearing collected by the bearing monitoring system and the main pipeline resistance data and the branch pipeline resistance data collected by the lubrication pipeline resistance acquisition sensors, and the data storage unit is used for storing the collected data and analysis and processing results. The lubrication device further comprises lubrication pipeline resistance acquisition sensors, the lubrication pipeline resistance acquisition sensors comprise first resistance sensors on the main pipelines and second resistance sensors on the branch pipelines, the first resistance sensors are used for monitoring whether the main pipelines of the bearing intelligent lubrication system are normal, and the second resistance sensors are used for monitoring whether the branch pipelines of the bearing intelligent lubrication system are normal.

2. The centralized bearing lubrication monitoring and control apparatus of claim 1, wherein, The device is a centralized bearing monitoring lubrication device, the control terminal of the device can simultaneously monitor and control a plurality of lubrication devices through a wireless network.

3. The centralized bearing lubrication monitoring and control apparatus of claim 1, wherein, The three-axis vibration temperature sensors are in communication connection with the collecting devices, the collector is in communication connection with the integrated control terminal through a 2400M wireless module, the integrated terminal module has two 2400M LORA wireless modules, and the two 2400M LORA wireless modules work in slave modes and passively receive data information transmitted by the collector, and a plurality of collectors can be distributed to different terminal module 2 2400M-LORA channels according to needs.

4. The centralized bearing lubrication monitoring and control apparatus of claim 1, wherein, ​

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