Precision lubrication system for bearings

Abstract

The utility model relates to a precision lubricating system for bearing belongs to the field of wind turbine operation and maintenance technology, and its strategy steps are as follows: S1, the subitem score calculation method, S2, obtains the equipment operation vibration state index S, S3, obtains the equipment vibration operation grease index G, S4, obtains the equipment operation temperature index T, S5, obtains the actual should compensate the grease amount Q. System is used for the bearing to carry out the injection lubricant, and the system includes the dynamic grease injection execution part, and the dynamic grease injection execution part includes the lubricating execution part and lubricating power part connected with pipeline, and the lubricating power part includes the grease injection pump and the oil storage tank connected with the constant quantity through the control valve fluid path, and the lubricating execution part is connected with the grease injection pump through the oil inlet pipeline a, and the lubricating execution part is connected with the oil storage tank through the pipeline b, and the utility model discloses the reasonable design, compact structure and convenient to use.

Description

Technical Field

[0001] This utility model relates to the field of wind turbine operation and maintenance lubrication technology, specifically to a precision lubrication system for bearings, and intelligent lubrication for key bearings of wind turbines. Background Technology

[0002] Wind turbines operate in complex outdoor environments for extended periods, and their key components, such as main shaft bearings and gearbox bearings, are subjected to high loads and variable speeds. The lubrication effect directly determines the bearing life and the stability of the turbine's operation.

[0003] Traditional wind turbine lubrication systems often employ a "timed and quantitative" grease injection mode, which involves injecting a fixed amount of grease according to a preset cycle (such as every 72 hours). This mode has significant drawbacks: on the one hand, when the bearing experiences a surge in lubrication demand due to increased load or rising ambient temperature, the fixed amount of grease cannot meet the demand, easily leading to dry friction and a sudden temperature rise in the bearing, causing jamming or wear failures; on the other hand, when the bearing is under low load and low temperature conditions, excessive grease injection will cause grease accumulation, increasing the bearing's operating resistance. At the same time, excess grease leakage will also cause environmental pollution and resource waste.

[0004] The publicly available grease-lubricated bearing system is complex, requiring at least two control systems. It cannot achieve coordinated control, resulting in a complex control system, redundant piping, numerous joints, and a high failure rate. Both main pipelines must function properly for the system to operate; it is impossible for the entire system to function if only one main pipeline is operational.

[0005] Therefore, it is impossible to achieve the requirement of grease injection as needed under different operating conditions of the bearing, resulting in insufficient lubrication under high load conditions and grease waste under low load conditions. Furthermore, in the existing operation and maintenance model, bearing fault detection mostly relies on regular manual inspections or simple over-limit alarms using temperature sensors, which cannot predict bearing deterioration trends in advance. When the temperature or vibration signal reaches the alarm threshold, the bearing has often already suffered irreversible damage, requiring shutdown and replacement, resulting in high operation and maintenance costs and power generation losses.

[0006] Traditional bearing waste grease recycling relies on the internal pressure of the bearing to squeeze it out, which can easily cause blockages. Even with an independent waste grease auxiliary recycling system, it can only achieve periodic and quantitative recycling, without being linked to the grease injection logic of the lubrication system.

[0007] Traditional equipment status monitoring typically relies on vibration, temperature, and noise. By the time abnormalities are detected, the bearings have often already suffered irreversible damage, requiring shutdown and replacement.

[0008] Traditional bearing grease condition monitoring requires personnel to extract a small amount of grease through the bearing bore for offline monitoring, which is time-consuming and labor-intensive. This is especially true for wind turbines, which typically require an interval of more than six months between inspections. Sampling at a single location is not continuous and has extremely low accuracy.

[0009] Therefore, there is an urgent need for an intelligent lubrication system that can simplify the oil circuit, achieve a good automatic adjustment lubrication system, and realize automated control of grease suction and discharge, thereby avoiding the vacuum or pressure mismatch that occurs in the grease suction and discharge of traditional control systems, so as to solve the pain points of traditional technology. Utility Model Content

[0010] The technical problem to be solved by this utility model is to provide a precision lubrication system for bearings. By effectively and efficiently circulating the grease inside the bearing, and by cleaning and replacing the grease inside the bearing through grease injection and discharge of waste grease, the operating environment of the bearing is improved, further deterioration is prevented, the control system is simplified, and joints and seals are reduced.

[0011] This invention improves the accuracy of detection by installing multiple waste grease auxiliary recycling systems on the bearing and continuously collecting and mixing waste grease at multiple points for real-time detection.

[0012] This utility model effectively integrates an intelligent lubrication system with a waste grease auxiliary recycling system. It can share a grease pump as a power source and automatically add grease and discharge waste grease according to the working status feedback of the bearing. To solve the above problems, the technical solution adopted by this utility model is as follows: A precision lubrication system for bearings, the system being used to add lubricant to the bearings; The system includes a dynamic grease injection actuator; The dynamic grease injection actuator includes a lubrication actuator connected to pipelines and a lubrication power unit; The lubrication and power unit includes a metered grease pump and an oil reservoir connected via a control valve fluid circuit; The lubrication actuator is connected to the grease pump via oil inlet line a; The lubrication actuator is connected to the oil reservoir via pipe b; Several grease inlets and grease suction outlets are distributed on the bearing; The lubrication actuator includes a grease distribution valve for lubricating the bearing and a grease suction device with a corresponding suction port; The grease extractor is used to remove bearing lubricating oil; The grease filling port is connected to the grease distribution valve via pipe C; The grease pump is connected to the inlet of the grease distribution valve and / or line e via inlet line a; The oil storage tank is connected to the inlet of the grease distribution valve via pipe b or pipe e.

[0013] Furthermore, the control valve is either a directional valve or a shut-off valve; When the control valve is a directional valve, a check valve is installed at the outlet of the directional valve; The reversing valve is installed on oil inlet line a and line b; When a shut-off valve is used as the control valve, the shut-off valve is installed on pipeline b. A valve plunger monitoring sensor is installed on the grease distribution valve; A pressure sensor is installed in pipeline e; The dynamic grease injection actuator is connected to a dynamic grease removal actuator via piping. The dynamic fat removal unit includes a waste oil collection device; The liposuction device is connected to a waste oil collection device via tubing d; e; the hydraulic chamber connection tubing of the liposuction device; Sensor components for real-time acquisition of bearing operating parameters, including a grease condition detection sensor installed on pipeline d, a vibration sensor and / or a temperature sensor installed at the bearing; The sensor assembly is electrically connected to the backend; the backend includes a processor. The processor is electrically connected to a controller for controlling the rotation of the motor; The processor is electrically connected to a data memory; The processor is electrically connected to the early warning and interaction unit.

[0014] Furthermore, the oil storage tank is equipped with a liquid level sensor; The back-end system is electrically connected to the liquid level sensor, the distribution valve plunger monitoring sensor, the control valve, the grease pump, the pressure sensor, the grease status detection sensor, the vibration sensor, and / or the temperature sensor.

[0015] Furthermore, the liposuction device includes a liposuction housing; A hydraulic cavity and an inner cavity are provided in the liposuction housing; A piston body with a spring return mechanism is movable within the inner cavity; A pipe a is connected to the hydraulic cavity, which pushes the piston to move, thereby realizing the linkage between liposuction and fat removal. A knob plug is connected to the outlet of the inner cavity; A sealing plug is connected to the knob plug by a spring. Under the action of the spring force, the sealing plug blocks the connection between the knob plug outlet and the inner cavity. A bypass hole is provided on the side wall of the liposuction housing, which is normally blocked and closed by a sealing plug; When the piston moves to the left, the sealing plug moves to the left against the spring force, thereby connecting the inner cavity with the bypass hole; Bypass hole connects to pipe d; The temperature sensor is installed at the contact point between the inner and outer rings of the bearing. The vibration sensor is a piezoelectric accelerometer, which is installed in the vertical and horizontal directions of the bearing housing respectively; The grease condition detection sensor integrates sensors for detecting metal impurities and moisture; a concentration block is installed on the pipe d; the grease condition detection sensor is inserted into the inlet of the liposuction device or discharged into the concentration block; The sensor assembly communicates with the backend via an RS485 bus; The background processor uses the GD32E50x series; Dynamic grease injection actuator: After receiving instructions from the backend, the grease injection pump starts working and delivers high-pressure grease through pipelines to the grease distribution valve. The backend monitors the operation feedback of the plunger sensor inside the grease distribution valve to achieve precise control of the grease injection volume.

[0016] After receiving instructions from the backend, the grease pump controls the operation of the grease pump, switches the control valve, and delivers high-pressure grease to the hydraulic chamber of the liposuction device as power to drive the liposuction device to work. Through negative pressure, the waste grease inside the bearing is extracted and transported to the waste grease collection device. The collected grease is detected by the grease condition detection sensor.

[0017] This invention achieves precise lubrication: by sensing the bearing condition in real time through a sensor assembly, this invention avoids "excessive waste" and "insufficient damage". Tests have shown that it can reduce grease consumption by 30% and extend bearing service life by 20%.

[0018] This invention transforms post-event maintenance into pre-event monitoring, reducing unplanned downtime of wind turbines. Practical application has shown that it can reduce operation and maintenance costs by 15%.

[0019] This invention enables full circulation of grease, avoids increasing the load power, and achieves precise and high-quality regulation.

[0020] This invention simplifies control by outputting high-pressure grease to drive a liposuction pump, thereby achieving active circulation of the grease.

[0021] This utility model is reasonably designed, low in cost, sturdy and durable, safe and reliable, simple to operate, time-saving and labor-saving, cost-saving, compact in structure and easy to use. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall design of this utility model.

[0023] Figure 2 This is a schematic diagram of the grease injection working structure of Embodiment 1 of this utility model.

[0024] Figure 3 This is a schematic diagram of the liposuction working structure of Embodiment 1 of this utility model.

[0025] Figure 4 This is a schematic diagram of the internal structure of the liposuction device of this utility model.

[0026] Figure 5 This is a schematic diagram of the working operation of the single-line lubrication system of this utility model.

[0027] The components include: 1. Grease pump; 2. Control valve; 3. Check valve; 4. Grease distribution valve; 5. Grease suction device; 6. Pressure sensor; 7. Grease status detection sensor; 8. Vibration sensor; 9. Temperature sensor; 10. Waste grease collection device; 14. Bearing; 1.1. Liquid level sensor; 4.1. Distribution valve plunger monitoring sensor; 14.1. Grease filling port; 14.2. Grease suction port; 15. Grease suction housing; 16. Piston body; 17. Inlet; 18. Inner cavity; 19. Sealing plug; 20. Knob plug; 21. Outlet; 22. Bypass hole; 23. Hydraulic chamber. Detailed Implementation

[0028] Example 1, such as Figure 1-5 A precision lubrication system for bearings, the system being used to apply lubricant to bearing 14; The system includes a dynamic grease injection actuator; Used to execute the above strategies; The dynamic grease injection actuator includes a lubrication actuator connected to pipelines and a lubrication power unit; The lubrication power unit includes a metered grease pump 1 and an oil reservoir connected via a control valve 2 hydraulic circuit; The lubrication actuator is connected to the grease pump 1 via the oil inlet line a; The lubrication actuator is connected to the oil reservoir via pipe b; Several grease inlets 14.1 and grease suction inlets 14.2 are distributed on the bearing 14; The lubrication actuator includes a grease distribution valve 4 for lubricating the bearing 14 and a grease suction device 5 corresponding to the grease suction port 14.2; The grease extractor 5 is used to remove the lubricating oil from the bearing 14; Grease filling port 14.1 is connected to grease distribution valve 4 via pipe c; Grease pump 1 is connected to the inlet of grease distribution valve 4 and / or line e via oil inlet line a; The oil storage tank is connected to the inlet of the grease distribution valve 4 or to pipeline e via pipeline b.

[0029] Among them, control valve 2 is a directional valve or a shut-off valve; When the control valve 2 is a directional valve, a check valve 3 is provided at the outlet of the directional valve; The reversing valve is installed on oil inlet line a and line b; When control valve 2 is a shut-off valve, the shut-off valve is installed on pipeline b; A distribution valve plunger monitoring sensor 4.1 is installed on the grease distribution valve 4; A pressure sensor 6 is installed in pipeline e; The dynamic grease injection actuator is connected to a dynamic grease removal actuator via piping. The dynamic fat removal unit includes a waste oil collection device 10; The liposuction device 5 is connected to the waste oil collection device 10 via the tube d; The bypass hole 22 of the liposuction device is connected to the tubing e; The sensor assembly is used to collect bearing operating parameters in real time, including a grease condition detection sensor 7 installed on the pipeline d, a vibration sensor 8 installed at the bearing 14, and / or a temperature sensor 9. The sensor assembly has an electrical connection to a backend system; the backend system includes a processor. The processor is electrically connected to a controller for controlling the rotation of the motor; The processor is electrically connected to a data memory; The processor is electrically connected to the early warning interaction unit, which can be connected via conventional circuits such as a PLC.

[0030] The oil storage tank is equipped with a liquid level sensor 1.1; The back-end is electrically connected to the liquid level sensor 1.1, the distribution valve plunger monitoring sensor 4.1, the control valve 2, the grease pump 1, the pressure sensor 6, the grease status detection sensor 7, the vibration sensor 8, and / or the temperature sensor 9, respectively. The liposuction device 5 includes a liposuction housing 15; A hydraulic cavity 23 and an inner cavity 18 are provided in the liposuction housing 15; A spring-returning piston body 16 is movably disposed in the inner cavity 18; A pipe a is connected to the hydraulic cavity 23, which pushes the piston body 16 to move, thereby realizing the linkage action of liposuction and lipo expulsion. A knob plug 20 is connected to the outlet 21 of the inner cavity 18; A sealing plug 19 is connected to the knob plug 20 via a spring. Under the action of the spring force, the sealing plug 19 blocks the connection between the outlet of the knob plug 20 and the inner cavity 18. A bypass hole 22 is provided on the side wall of the liposuction housing 15, which is normally blocked and closed by the sealing plug 19; When the piston body 16 moves to the left, the sealing plug 19 moves to the left against the spring force, thereby connecting the inner cavity 18 with the bypass hole 22. Bypass hole 22 connects to pipe d; Temperature sensor 9 is installed at the contact point between the inner and outer rings of the bearing. Vibration sensor 8 is a piezoelectric accelerometer, which is installed in the vertical and horizontal directions of the bearing housing respectively; The grease condition sensor 7 integrates sensors for detecting metal impurities and moisture; a concentration block is set on the pipeline d; the grease condition sensor 7 is inserted into the inlet of the liposuction device 5 or discharged into the concentration block; The sensor assembly communicates with the backend via an RS485 bus; Its backend MCU uses the GD32E50x series; Dynamic grease injection actuator: After receiving the command, the grease injection pump starts working and delivers high-pressure grease through the pipeline to the grease distribution valve 4. The background monitors the working feedback of the plunger sensor inside the grease distribution valve to achieve precise control of the grease injection volume.

[0031] After receiving instructions from the backend, the grease pump 1 controls the operation of the grease pump 1 and the control valve 2 reverses, delivering high-pressure grease to the hydraulic chamber 23 of the liposuction device 5 as power to drive the liposuction device 5 to work. The waste grease inside the bearing 14 is extracted through negative pressure and delivered to the waste grease collection device 10. The collected grease is detected by the grease status detection sensor 7.

[0032] Among them, such as Figure 1-3 Dual-wire working principle Figure 2 As part of the grease injection process, pump 1 is started, and pipeline a passes through control valve 2, check valve 3, and grease distribution valve 4 to reach each grease inlet 14.1 for grease injection. At the same time, hydraulic chamber 23 is reset, and the lubricant returns to the oil storage tank through pipelines e and b. The grease suction port 14.2 enters the inner cavity 18 through inlet 17.

[0033] Of course, conventional components such as one-way valves can be added to the liposuction port 14.2 and the inlet 17.

[0034] When control valve 2 reverses, pipeline a enters hydraulic chamber 23 through control valve 2 and pipeline e, thereby causing piston body 16 to overcome spring force and move to the left, squeezing inner cavity 18. Sealing plug 19 overcomes spring force, causing bypass hole 22 to connect with inner cavity 18, allowing lubricant in inner cavity 18 to be discharged into pipeline d, passing through grease status detection sensor 7, and entering waste grease collection device 10.

[0035] against Figure 5 In this process, control valve 2 is shut off, and pipeline a passes through pipeline e and each grease inlet 14.1. Piston body 16 overcomes spring force and moves to the left, squeezing inner cavity 18. Sealing plug 19 overcomes spring force, so that bypass hole 22 communicates with inner cavity 18, so that lubricant in inner cavity 18 is discharged into pipeline d, passes through grease status detection sensor 7, and enters waste grease collection device 10.

[0036] After the control valve 2 is turned on, the hydraulic chamber 23 is reset, and the lubricant enters the inner cavity 18 from the grease suction port 14.2 through the inlet 17.

[0037] Example 3, as a practical application, such as Figure 1-5 A precision lubrication system for bearings based on equipment health status mainly consists of a grease pump 1, a control valve 2, a grease distribution valve 4, a grease suction device 5, a pressure sensor 6, a grease status detection sensor 7, a vibration sensor 8, a temperature sensor 9, a waste grease collection device 10, and a bearing 14. The system can be divided into a dynamic grease injection actuator, a dynamic grease discharge actuator, a sensor assembly, and collaborative work between various back-end components, as detailed below. Control valve 2 is a two-position four-solenoid valve.

[0038] Sensor Components: Used for real-time acquisition of bearing operating parameters, including a temperature sensor (using a PT100 platinum resistance sensor, installed at the contact point between the inner and outer rings of the bearing, measuring range -50℃~200℃, accuracy ±0.5℃), a vibration sensor (using a piezoelectric accelerometer, installed vertically and horizontally in the bearing housing, measuring frequency range 0.1Hz~10kHz, sensitivity 100mV / g), and a grease condition detection sensor (integrating metal impurity detection and moisture detection sensors, inserted into the inlet of the grease extractor or inside the grease extractor discharge collection block); each sensor communicates with the backend via an RS485 bus, with a data transmission rate ≥9600bps, ensuring real-time parameter accuracy.

[0039] The background dynamic grease injection execution unit includes a quantitative grease injection pump 1, a grease distribution valve 4 (progressive, single-line, or double-line types are all available, with an injection accuracy of ±0.02mL / time and an injection pressure range of 0~35MPa), a distribution valve plunger monitoring sensor, and grease tubing (using low-temperature resistant high-pressure hoses, with an operating temperature of -40℃~80℃). After receiving instructions from the background unit, the grease injection pump starts working and delivers high-pressure grease through the tubing to the grease distribution valve 4. The background unit monitors the operation feedback of the plunger sensor inside the grease distribution valve to achieve precise control of the grease injection volume.

[0040] Dynamic grease removal execution unit: includes a quantitative waste grease collection device 10 and grease pipeline; after receiving instructions from the background, the grease pump controls the operation of the grease pump, the two-position four-way solenoid valve 2 switches, and the high-pressure grease is delivered to the liposuction device as power to drive the liposuction device to work. The waste grease inside the bearing is extracted by negative pressure and delivered to the waste grease collection device 10. All collected grease is detected by the grease status detection sensor 7.

[0041] The back-end power supply can be connected to an early warning interaction unit, which includes a local audible and visual alarm.

[0042] This utility model is described in detail for the purpose of making the disclosure clearer, and the prior art will not be listed one by one.

[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. It is obvious to those skilled in the art that multiple technical solutions of this utility model can be combined. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model. All technical contents not described in detail in this utility model are publicly known technologies.

Claims

1. A precision lubrication system for bearings, characterized in that: The system is used to lubricate the bearing (14); The system includes a dynamic grease injection actuator; The dynamic grease injection actuator includes a lubrication actuator connected to pipelines and a lubrication power unit; The lubrication power unit includes a metered grease pump (1) and an oil reservoir connected via a control valve (2) fluid circuit; The lubrication actuator is connected to the grease pump (1) via the oil inlet pipe a; The lubrication actuator is connected to the oil reservoir via pipe b; Several grease inlets (14.1) and grease suction inlets (14.2) are distributed on the bearing (14). The lubrication actuator includes a grease distribution valve (4) for lubricating the bearing (14) and a grease suction device (5) corresponding to the grease suction port (14.2). The grease extractor (5) is used to extract the lubricating oil from the bearing (14); The grease filling port (14.1) is connected to the grease distribution valve (4) via pipe c.

2. The precision lubrication system for bearings according to claim 1, characterized in that: The grease pump (1) is connected to the inlet of the grease distribution valve (4) and / or the pipeline e via the oil inlet pipeline a; The oil storage tank is connected to the inlet of the grease distribution valve (4) or the pipeline e via pipeline b.

3. The precision lubrication system for bearings according to claim 2, characterized in that: The control valve (2) is a directional valve or a shut-off valve; When the control valve (2) is a directional valve, a check valve (3) is provided at the outlet of the directional valve. The reversing valve is installed on oil inlet line a and line b; When the control valve (2) is a shut-off valve, the shut-off valve is installed on pipeline b.

4. The precision lubrication system for bearings according to claim 2 or 3, characterized in that: A distribution valve plunger monitoring sensor (4.1) is installed on the grease distribution valve (4). A pressure sensor (6) is installed in pipeline e; The dynamic grease injection actuator is connected to a dynamic grease removal actuator via piping. The dynamic fat removal unit includes a waste oil collection device (10). The liposuction device (5) is connected to the waste oil collection device (10) through the pipe d; The hydraulic chamber (23) of the liposuction device (5) is connected to the tubing e.

5. The precision lubrication system for bearings according to claim 4, characterized in that: The system also includes a sensor assembly for real-time acquisition of bearing operating parameters, including a grease condition detection sensor (7) installed on the pipeline d, a vibration sensor (8) installed at the bearing (14), and / or a temperature sensor (9).

6. The precision lubrication system for bearings according to claim 5, characterized in that: The oil storage tank is equipped with a liquid level sensor (1.1). The back-end is electrically connected to the liquid level sensor (1.1), the distribution valve plunger monitoring sensor (4.1), the control valve (2), the grease pump (1), the pressure sensor (6), the grease status detection sensor (7), the vibration sensor (8), and / or the temperature sensor (9).

7. The precision lubrication system for bearings according to claim 6, characterized in that: The liposuction device (5) includes a liposuction housing (15); A hydraulic cavity (23) and an inner cavity (18) are provided in the liposuction housing (15); A spring-returning piston body (16) is movably disposed in the inner cavity (18); A pipe a is connected to the hydraulic cavity (23), which pushes the piston body (16) to move, thereby realizing the linkage action of liposuction and liposuction.

8. The precision lubrication system for bearings according to claim 7, characterized in that: A knob plug (20) is connected to the outlet (21) of the inner cavity (18). A sealing plug (19) is connected to the knob plug (20) by a spring. Under the action of the spring force, the sealing plug (19) blocks the connection between the outlet of the knob plug (20) and the inner cavity (18).

9. The precision lubrication system for bearings according to claim 8, characterized in that: A bypass hole (22) is provided on the side wall of the liposuction housing (15), which is normally blocked and closed by the sealing plug (19). Bypass hole (22) connects to pipe d; Temperature sensor (9) is installed at the contact point between the inner and outer rings of the bearing; The vibration sensor (8) is a piezoelectric accelerometer, which is installed in the vertical and horizontal directions of the bearing housing.

10. The precision lubrication system for bearings according to claim 9, characterized in that: The grease state detection sensor (7) integrates the detection of metal impurities and moisture; a concentration block is set on the pipeline d; the grease state detection sensor (7) is inserted into the inlet of the liposuction device (5) or discharged into the concentration block.

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