DEVICE FOR PUMPING LUBRICANT WITH PRESSURE LUBRICATION MECHANISM AND PUMP

Abstract

Device (300, 2500, 2900) for pumping lubricant, comprising: a container (304, 2504, 2930) with a tank (2518, 2932) with a side wall (310, 2520, 2936) and with an interior (2536) for receiving lubricant, a stirrer (320, 2600, 2940) that is rotatable in the container; a pressure lubrication mechanism (330, 2630) on the stirrer which is operational when the stirrer is rotated to exert a pressure force that forces lubricant from the container along a flow path (2586) defined by a tubular channel extending away from an inlet opening of the tubular channel; a pump housing (306, 2506, 2902) with an upper wall (2540, 2950), wherein the upper wall (2540, 2950) defines a bottom of the interior (2536) of the container to be in contact with the lubricant contained inside the container (304, 2504, 2930), wherein the upper wall (2540, 2950) includes an opening (2582, 2954) which forms the inlet opening of the tubular channel, a pump located under the reservoir to pump lubricant from the reservoir to a lubricant distribution system; wherein the pump comprises a cylinder (334, 2508) with a cylinder inlet (2570, 2920) aligned with the opening in the upper wall of the pump housing and in fluid communication with the interior of the container (304, 2504, 2930) via the flow path (2586) defined by the tubular channel, a cylinder bore (338, 2566, 2910) and a piston (384, 1230, 1330, 2512, 2908) which is movable in the cylinder bore, which is arranged at an outlet opening of the flow path defined by the tubular channel, by a pump stroke and a return stroke, wherein the cylinder inlet has a surface (2574) in sealing engagement with an opposite surface (2578) of the upper wall of the pump housing to separate the tubular channel from the upper wall (2540, 2950) to seal the cylinder inlet; wherein the cylinder bore is connected to the interior of the container via the flow path (2586) defined by the tubular channel, whereby the rotation of the stirrer causes the pressure lubrication mechanism to exert a pressure force on the stirrer, which pushes the lubricant along the flow path defined by the tubular channel, such that the movement of the piston during the return stroke generates a reduced pressure in the cylinder bore, which exerts a tensile force on the lubricant along the flow path defined by the tubular channel, wherein the pressure and tensile forces together move the lubricant along the flow path defined by the tubular channel from the container (304, 2504, 2930) into the cylinder bore; wherein the flow path defined by the tubular channel (2586) is a generally straight flow path with a length of less than 7.62 cm.

Description

AREA OF INVENTION

[0001] The present invention relates generally to a device for providing lubricant and in particular to an automatic lubrication system for automatically pumping lubricant to a plurality of lubrication points. GENERAL STATE OF THE ART

[0002] This invention is particularly applicable in automatic lubrication systems for supplying lubricant to multiple lubrication points at predetermined intervals and / or in predetermined quantities. Lincoln Industrial markets such automated systems under the trademarks Quicklub®, Centro-Matic®, and Helios®. The Quicklub® system comprises a reservoir for holding a lubricant supply, an agitator for stirring the lubricant, and an electric or pneumatic pump for pumping lubricant from the reservoir to one or more progressive metering (distributing) valves, each of which dispenses lubricant to multiple lubrication points. For further details regarding an exemplary Quicklub® system, reference may be made to U.S. Patent 6,244,387, which is incorporated herein by reference.The Centro-Matic® system is similar to a Quicklub® system, except that lubricant is delivered from the pump through a single supply line to injectors that dispense a measured quantity of lubricant to a single lubrication point. For further details regarding an exemplary Centro-Matic® system, reference can be made to US Patent 6,705,432, which is incorporated herein by reference. The Helios® system is a dual-line system. Document DE 20 2008 000 748 U1 discloses a lubricant pump for delivering lubricant to multiple lubrication points. The lubricant pump has a lubricant reservoir with a first housing section and a second housing section, wherein pump elements are arranged in the second housing section such that the respective suction area is located in the lubricant.Document EP 2 128 443 A1 describes a pump element which is particularly suitable for use as a lubricant dispenser and is used, for example, in metering pumps of discharge systems.

[0003] Although these systems have proven reliable and commercially successful, there is a need for an improved pump unit that can be used with a variety of lubricant distribution systems and features a simplified design. BRIEF SUMMARY OF THE INVENTION

[0004] In one aspect, the present invention relates to a device for supplying lubricant. The device includes a container having an interior space for receiving lubricant. The device also includes a pump for pumping lubricant from the container into a lubricant distribution system. The pump includes a cylinder having a cylinder bore. The pump also includes a cylinder inlet that communicates with the interior of the container to provide a flow of lubricant from the container into the cylinder bore. The pump further includes a cylinder outlet. The pump also includes a piston that is movably arranged in the cylinder bore. The pump further includes a check valve in the cylinder bore between the piston and the cylinder outlet to block backflow through the outlet.The pump also includes a relief channel located upstream of the check valve, which communicates with the cylinder bore to relieve the lubricant distribution system. The pump further includes a linear position drive mechanism for moving the piston forward within the cylinder bore by means of a pump stroke to pump lubricant through the cylinder outlet into the lubricant distribution system, backward by means of a non-relieving return stroke where the relief channel does not communicate with the interior of the reservoir, and backward by means of a relieving return stroke where the relief channel communicates with the interior of the reservoir. The device further includes a control unit for calibrating and controlling the operation of the linear position drive mechanism.

[0005] In a further aspect, the present invention includes a method for supplying lubricant to a pressure-relieving lubricant distribution system and to a non-pressure-relieving lubricant distribution system. This method involves operating a linear position drive mechanism to move a piston in a cylinder bore through a pump stroke, pumping lubricant through an outlet of the cylinder bore into the pressure-relieving lubricant distribution system and / or to the non-pressure-relieving lubricant distribution system. The method also includes operating the linear position drive mechanism to move the piston through a non-pressure-relieving return stroke with a first length, during which the non-pressure-relieving lubricant distribution system is not relieved.The procedure further includes calibrating the linear position drive mechanism and operating the calibrated linear position drive mechanism to move the piston through a relieving return stroke with a second length that differs from the first length and during which the relieving lubricant distribution system is relieved.

[0006] In one aspect, the present invention relates to a device for pumping lubricant, comprising a container with an interior for receiving the lubricant. The device also includes an agitator rotatably mounted within the container. One advantage of the agitator is that it maintains a sufficiently low viscosity of the lubricant to allow it to flow more easily. Under colder environmental conditions, the lubricant can become stiffer or more viscous. The agitator fluidizes the lubricant, thereby enabling the lubricant pump to operate more efficiently. The device further includes a pressure lubrication mechanism on the agitator, which can be operated during the rotation of the agitator to exert a thrust force that pushes the lubricant from the container along a defined flow path.The device also includes a pump located below the reservoir for pumping lubricant from the reservoir into the lubricant distribution system. The pump comprises a cylinder with a bore and a piston that moves within the bore through a pumping stroke and return stroke. The bore communicates with the interior of the reservoir via the defined flow path. The rotation of the agitator causes the pressure lubrication mechanism on the agitator to exert a thrust force that pushes the lubricant along the defined flow path. The piston's return stroke creates a reduced pressure in the bore, exerting a pull force that draws lubricant along the defined flow path. The thrust and pull forces combine to move lubricant from the reservoir into the bore along the defined flow path.

[0007] In another aspect, the present invention includes a method for pumping lubricant from a container, which involves rotating an agitator within the container to cause a pressure lubrication mechanism on the agitator to exert a thrust force that pushes lubricant along a defined flow path from the container into a cylinder bore. The method also includes moving a piston in the cylinder bore by means of a pump stroke. The method further includes moving the piston by means of a return stroke to generate a reduced pressure in the cylinder bore. The reduced pressure exerts a tensile force that draws lubricant along the defined flow path. The thrust and tensile forces are combined to move lubricant along the defined flow path into the cylinder bore.

[0008] In one aspect, the present invention relates to a lubricant supply system comprising a reservoir for receiving lubricant. The reservoir has a reservoir outlet. The system also includes a pump comprising a cylinder with a cylinder bore, a cylinder inlet communicating with the reservoir outlet to provide a flow of lubricant from the reservoir into the cylinder bore, a cylinder outlet, and a piston movably arranged within the cylinder bore. The system further includes a lubricant supply system communicating with the cylinder outlet to supply lubricant. The system also includes a drive mechanism comprising a stepper motor for moving the piston back and forth within the cylinder bore. The system further includes a sensor for detecting a system condition and providing a condition signal.The system also includes an alarm. Furthermore, the system includes a control unit for regulating the motor's operation by selectively activating the motor to move the piston back and forth. The control unit responds to the condition signal by modifying system operation, for example, by selectively activating the alarm when the condition signal falls outside a predefined range.

[0009] In another aspect, the present invention includes a lubricant supply system comprising a reservoir for receiving lubricant. The reservoir has a reservoir outlet. The system also includes a pump including a cylinder defining a cylinder bore, a cylinder inlet communicating with the reservoir outlet to provide a flow of lubricant from the reservoir into the cylinder bore, a cylinder outlet, and a piston movably arranged in the cylinder bore. The system also includes a lubricant supply system.The system communicates with the cylinder outlet to supply lubricant. It further includes a drive mechanism, including a motor, for moving the piston back and forth within the cylinder bore. The system also includes a sensor for detecting a system condition and providing a condition signal. The system further includes an alarm. Additionally, the system includes a controller for regulating the motor's operation by selectively activating the motor to move the piston back and forth. The controller responds to the condition signal by, for example, selectively activating the alarm to modify system operation when the condition signal is outside a predefined range. The sensor comprises at least one or more of the following: a pressure sensor that monitors the lubricant pressure of the lubricant supply system,wherein the condition signal is a pressure signal and wherein the controller responds to the pressure signal by activating the alarm when the pressure signal indicates that the lubricant pressure is less than a minimum pressure; a pressure sensor that monitors a lubricant pressure at the pump, wherein the condition signal is a pressure signal and wherein the controller responds to the pressure signal by activating the alarm when the pressure signal indicates that the lubricant pressure at the pump is higher than a maximum pressure; a motion sensor that monitors a movement of the piston, wherein the condition signal is a movement signal and wherein the controller responds to the movement signal by activating the alarm when the movement signal indicates that the piston movement is less than a minimum movement; a level sensor that monitors a lubricant level of the reservoir,wherein the condition signal is a level signal and wherein the controller responds to the level signal by activating the alarm when the level signal indicates that the lubricant level is below a minimum level; and a pressure sensor that monitors the lubricant pressure of the lubricant supply system, wherein the condition signal is a pressure signal and wherein the controller responds to the pressure signal by activating the alarm when the pressure signal indicates that the lubricant pressure is below a minimum pressure after a certain period of motor pump operation.

[0010] In another aspect, the present invention includes a lubricant supply system comprising a reservoir for receiving lubricant. The reservoir includes a reservoir outlet. The system also includes a pump including a cylinder defining a cylinder bore, a cylinder inlet communicating with the reservoir outlet to provide a flow of lubricant from the reservoir into the cylinder bore, a cylinder outlet, and a piston movably arranged within the cylinder bore. The system further includes a lubricant supply system communicating with the cylinder outlet and comprising a plurality of valves, each used for supplying lubricant. The system also includes a drive mechanism including a motor for moving the piston back and forth within the cylinder bore.The system also includes a controller for regulating the motor's operation by selectively activating the motor to move the piston back and forth. The system further includes a CAN (Controller Area Network) bus connected to the controller. The system also includes a power supply. Additionally, the system includes a power bus connected to the power supply. The system further includes multiple actuators, each assigned to one of the valves to open or close the corresponding valve. The system also includes multiple CAN relays, each connected to the power bus and to one or more actuators to selectively activate the connected actuators to open and close the valves assigned to those actuators in order to supply lubricant.The system also includes multiple CAN modules, each connected to and controlling one or more CAN relays. Each CAN module is connected between the CAN bus and its corresponding CAN relay to control its relay in response to instructions provided by the controller via the CAN bus.

[0011] In one aspect, the present invention relates to a device for supplying lubricant. The device comprises a container, including a tank, for receiving lubricant. The container includes an outlet for dispensing lubricant from the container. The device also comprises a pump assembly, including a housing having a thermally conductive top wall on which the container is mounted. The top wall has an upper surface facing the container and a lower surface opposite the upper surface. The pump assembly also includes a lubricant pump mounted in the housing for pumping lubricant from the tank through the container outlet and to a lubrication point. The pump includes an inlet that communicates with the container outlet.The arrangement also includes a heater that is mounted in the housing in direct thermal contact with the top wall of the housing to heat lubricant located in the tank of the container before it flows through the container outlet.

[0012] In one aspect, the present invention relates to a device for supplying lubricant, comprising a container for receiving lubricant. The container has a container outlet. The device also includes a pump, which includes a cylinder defining a cylinder bore, a cylinder inlet communicating with the container outlet to provide a flow of lubricant from the container into the cylinder bore, a cylinder outlet, and a piston movably arranged in the cylinder bore. The device further includes a drive mechanism, including a motor for driving the pump, such as a stepper motor for moving the piston back and forth in the cylinder bore. The stepper motor has a continuous operating range.The device further includes a controller for regulating the operation of the stepper motor by selectively applying pulse-width modulated (PWM) pulses to the stepper motor to control its speed and torque. The device also includes a pressure sensor to detect the pressure of the supplied lubricant and to provide a pressure signal indicating the pressure at the outlet. The controller responds to the pressure signal by selectively applying PWM pulses to the stepper motor to vary its speed and torque as a function of the pressure signal, by applying PWM pulses whose power corresponds to the continuous operating range of the stepper motor.The controller also responds to the pressure signal by selectively applying PWM pulses to the stepper motor to vary its speed and torque as a function of the pressure signal. This is achieved by applying overdrive PWM pulses for a specific period. These overdrive PWM pulses exhibit an overdrive power level higher than the stepper motor's continuous operating range.

[0013] In another aspect, the present invention includes a device for supplying lubricant, comprising a reservoir for receiving lubricant. The reservoir has a reservoir outlet. The device also includes a pump comprising a cylinder defining a cylinder bore, a cylinder inlet communicating with the reservoir outlet to provide a flow of lubricant from the reservoir into the cylinder bore, a cylinder outlet, and a piston movably arranged within the cylinder bore. The device further includes a drive mechanism, including a stepper motor for moving the piston back and forth within the cylinder bore. The device also includes a controller for controlling the operation of the stepper motor by selectively applying PWM pulses to the stepper motor to control the motor's speed and torque.The controller includes a memory that stores a speed / pressure profile for the stepper motor. The device also includes a pressure sensor to detect the pressure at the cylinder bore outlet and provide a pressure signal indicating the outlet pressure. The controller responds to this pressure signal by selectively applying PWM pulses to the stepper motor to vary its speed and torque as a function of the pressure signal and the profile. This variation is achieved by applying PWM pulses with a power output within the stepper motor's continuous operating range.

[0014] The summary above is provided to introduce, in simplified form, a selection of concepts that are explained in more detail in the full description below. This summary is not intended to identify key properties or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Other objects and features are evident and partially illustrated below. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] They show: Fig. 1 A schematic view of a conventional automated lubrication system including distribution valves for directing lubricant to lubrication points; Fig. 2 a schematic view of a conventional automated lubrication system including injectors for directing lubricant to lubrication points; Fig. 3 a perspective view of a first embodiment of a pump unit of this invention; Fig. 4. A view from below of the pump unit Fig. 3; Fig. 5 a cross-section of the pump unit Fig. 3; Fig. 6 an enlarged section from Fig. 5, which represents a linear drive mechanism of the pump unit; Fig. 7 a projection of the linear drive mechanism along the plane 7-7 from Fig. 6; Fig. 8 an enlarged section of the linear drive mechanism showing a calibration mechanism; Fig. 9 a Fig. 8 an enlarged section of the linear drive mechanism representing a piston at the limit of a return stroke; Fig. 10 a schematic view of a lubrication system of the present invention including a distributor valve distribution system; Fig. 11 a schematic view of a lubrication system of the present invention including an injector distribution system; Fig. 12 a schematic view of a lubrication system of the present invention including a CAN bus distribution system divided into zones; Fig. 13 A perspective view of a valve body and a plurality of electronically controlled valves in the CAN bus lubricant distribution system Fig. 12 can be used; Fig. 14 a cross-section of the valve body and the electronically controlled valves Fig. 13; Fig. 15 a sketch similar to Fig. 14, but rotated by 90 degrees; Fig. 16 a schematic view of a lubrication system divided into zones according to the present invention, wherein each zone includes a distributor valve distribution system; Fig. 17 a schematic view of a zoned lubrication system of the present invention, wherein one zone includes a CAN bus lubricant distribution system and another zone includes a distributor valve distribution system; Fig. 18 a schematic view of a lubrication system divided into zones according to the present invention, wherein each zone includes an injector distribution system; Fig. 19 a schematic view of a zoned lubrication system of the present invention, wherein one zone includes a CAN bus lubricant distribution system and another zone includes an injector distribution system; Fig. 19A a schematic view of a lubrication system of the present invention divided into several zones, wherein one zone includes an injector distribution system with a single line and another zone includes an injector distribution system with a double line; Fig. 19B a schematic view of a lubrication system of the present invention divided into several zones, wherein one zone includes a distributor valve manifold system with a single line and another zone includes an injector manifold system with a double line; Fig. 19C a schematic view of a lubrication system of the present invention with a single zone including a double-line injector distribution system; Fig. 20 a schematic view of a first alternative drive mechanism for a pump unit; Fig. 21 a schematic view of a second alternative drive mechanism for a pump unit; Fig. 22 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a closed-loop injector system and internal pressure transducer; Fig. 23 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a discharge meter test for a lubrication system comprising a closed-loop injector system and internal pressure transducer; Fig. 24 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a maximum pressure test for a lubrication system comprising a closed-loop injector system with internal pressure transducer or a non-injector system (e.g. a distributor valve manifold system) with open-loop control and internal pressure transducer; Fig. 25 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a full stroke test of a piston for a lubrication system comprising an injector system with closed control loop and internal pressure transducer or a non-injector system with open control loop and internal pressure transducer; Fig. 26 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a reservoir level test for a lubrication system comprising a closed-loop injector system or an open-loop non-injector system, each with or without an internal pressure transducer; Fig. 27 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a cycle (i.e., injector reset) run-through test for a lubrication system comprising a closed-loop injector system with internal pressure transducer or a non-injector system with open-loop control and internal pressure transducer; Fig. 28 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a lubricant reservoir stiffness test for a lubrication system comprising an injector system with closed control loop and internal pressure transducer or a non-injector system with open control loop and internal pressure transducer; Fig. 29 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a non-injector system with open control loop and internal pressure transducer; Fig. 30 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a closed-loop injector system without an internal pressure transducer; Fig. 31 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a discharge meter test for a lubrication system comprising a closed-loop injector system without an internal pressure transducer; Fig. 32 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a maximum pressure test for a lubrication system comprising a closed-loop injector system without an internal pressure transducer or a non-injector open-loop system without an internal pressure transducer; Fig. 33 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a full stroke test of a piston for a lubrication system comprising a closed-loop injector system without an internal pressure transducer or a non-injector open-loop system without an internal pressure transducer; Fig. 34 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a cycle (i.e., injector reset) run-through test for a lubrication system comprising a closed-loop injector system without an internal pressure transducer or a non-injector open-loop system without an internal pressure transducer; Fig. 35 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a lubricant reservoir stiffness test for a lubrication system comprising a closed-loop injector system without an internal pressure transducer or a non-injector open-loop system without an internal pressure transducer; Fig. 36 a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a non-injector open-loop control system without an internal pressure transducer; Fig. 36A a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnostics for a CAN bus lubrication system having control valves without an internal pressure transducer, as in Fig. 19 shown; Fig. 37 a block diagram of an embodiment of a CAN bus lubrication system 2300 of the invention for providing lubricant, wherein the system includes several zones of control valves; Fig. 37A a block diagram of another embodiment of a CAN bus lubrication system 2300 of the invention for providing lubricant, wherein the system includes a zone of distribution valves and a zone of injectors; Fig. 38 a perspective view of another embodiment of a pump unit of this invention; Fig. 39 a vertical section through the pump unit Fig. 38, which represents a refill port for refilling a container of the unit; Fig. 40 an enlarged section of Fig. 39; Fig. 41 a vertical section through the pump unit Fig. 38, which shows a linear drive mechanism of the pump unit; Fig. 42 an enlarged section from Fig. 39, which shows the linear drive mechanism; Fig. 43 an enlarged section from Fig. 41, which shows a cylinder inlet of the drive mechanism; Fig. 44 a similar view to that in Fig. 42, but rotated by 90 degrees to show an elongated section of the cylinder intake; Fig. 45 a top view of a stirring mechanism of the pump unit; Fig. 46 a vertical section through the drive motor and associated components of the stirrer; Fig. 47 an enlarged vertical section along the plane 47-47 from Fig. 45, which shows a pressure lubrication mechanism on the stirrer; Fig. 48 a graph comparing the results of tests carried out using a prior art pump and a pump unit according to this invention; Fig. 49 an underside view of the pump unit Fig. 38; Fig. 50 an enlarged vertical section along the plane 50-50 from Fig. 49; Fig. 51 an enlarged vertical section showing components of the linear drive mechanism, including drive spindle, piston, tappet housing and tappet; Fig. 52 a perspective view of the drive spindle; Fig. 53 a sectional view of the pestle; Fig. 54 a vertical section along the plane 54-54 from Fig. 42; Fig. 55A a bottom view of a pump unit which includes a temperature sensor and a heater; Fig. 55B a partial cross-section of the pump unit along the plane 55B-55B from Fig. 55A; Fig. 55C a perspective view of a pump unit having a separate tank; Fig. 55D a partial cross-section of the pump unit along the plane 55D-55D from Fig. 55A; Fig. 55E a partial cross-section of an alternative embodiment of a pump unit along the plane 55B-55B Fig. 55A; Fig. 56 a graph showing a curve of the power of a stepper motor over time and the continuous operating range of the stepper motor; Fig. 57 a graph showing speed in rpm (revolutions per minute) compared to pressure in psi of an operating profile of a stepper motor according to the invention and a tilting torque curve of the stepper motor; and Fig. 58 a graph that represents pressure in psi compared to speed in rpm of a tilting torque curve of the stepper motor.

[0016] Identical components are identified throughout the drawings with the same reference numbers. DETAILED DESCRIPTION

[0017] Fig. Figure 1 shows a conventional Quicklub® system, generally designated 100, comprising a pump unit 110 that pumps lubricant through a lubricant supply line 114 to a master distributor valve, generally designated 118, which has an inlet 120 and several outlets 124 connected via lines 128 to the inlets 130 of additional (slave) distributor valves, generally designated 134. The distributor valves 134 are connected via lines 138 to bearings 144 or other lubrication points. The number of distributor valves 134 used varies depending on the number of lubrication points to be served.

[0018] The pump unit 110 includes a reservoir 150 for receiving lubricant (e.g., grease), an agitator 156 for stirring the lubricant in the reservoir, and an expandable chamber pump 158 in a pump housing 160 below the reservoir. A motor 164 in the pump housing rotates the agitator 156 to stir the lubricant in the reservoir. The motor 164 also rotates an eccentric mechanism 170 to move a spring-loaded piston in a series of pump strokes to pump lubricant through the supply line 114 to the distributor valve(s) 118, 134. The mechanism for driving the agitator 156 and the eccentric mechanism 170 includes a relatively bulky drive 180 comprising several gears. The pump unit 110 includes a programmable controller for controlling the operation of the motor 164 and for receiving signals from a proximity switch 186, which monitors the operation of the master distribution valve 118.

[0019] Fig. Figure 2 shows a conventional Centro-Matic® system, generally designated as 200, comprising a pump unit 210 that pumps lubricant through a lubricant supply line 214 to a plurality of injectors 130, each injector having an inlet communicating with the lubricant supply line 214 via channels in a bend 132, and an outlet 138 communicating with a bearing 155 or other lubrication point via a line 144. The pump unit 210 is similar to the pump unit 110 described above.

[0020] Fig. Figures 3-9 show an apparatus of the present invention comprising a pump unit 300 for supplying lubricant to various types of lubricant distribution systems (e.g., progressive systems, injector systems, CAN bus systems, dual-line systems, and combinations thereof). In general, the pump unit 300 comprises a reservoir, generally designated 304, for receiving a supply of lubricant (e.g., grease), and a pump housing 306 below the reservoir for accommodating various pump components of the unit, as described below. The pump housing 306 includes a pair of mounting flanges 308 ( Fig. 3) to secure the pump unit in an upright position to a suitable structure.

[0021] In the embodiment from Fig. The container 304 comprises a cylindrical side wall 310, an open top 312 for filling the container with lubricant, a lower wall 314, and an outlet 316 in the lower wall for draining the lubricant from the container. A stirrer, generally designated 320, is provided to stir the lubricant in the container. The stirrer 320 comprises a pivot point 322, which is driven by a first drive mechanism 326 ( Fig. 4) in the pump housing 320, which can be rotated about a vertical axis, an arm 328 extending laterally outward from the center of rotation along the lower wall 314, and a wiper 330 on the arm. The wiper 330 has a lower blade section 330a, which is beveled downwards toward the lower wall 314, and an upper section 330b, which extends upwards along the side wall 310 of the container. The rotation of the agitator fluidizes the lubricant in the container. The lower blade section 330a of the wiper 330 also forces lubricant downwards through the outlet 316 of the container.

[0022] With reference to Fig. 4 Inside the pump housing 306, a temperature sensor 332 is attached directly to the lower wall 314 of the container 304 in order to measure the temperature of the lower wall and thus the temperature of the lubricant in the container.

[0023] With reference to Fig. 5 and Fig. 6 is a pump cylinder, generally designated 334, attached directly to the lower wall 314 of the reservoir 304 within the pump housing. In the illustrated embodiment, the pump cylinder 334 is a two-part assembly comprising a first inlet part 334a and a second outlet part 334b, which is screwed to the inlet part. The two parts have longitudinal bores that together define a central longitudinal cylinder bore 338. The inlet cylinder part 334a has a radial bore 340 that defines a cylinder inlet which communicates with the reservoir outlet 316 to provide a flow of lubricant from the reservoir 304 directly (i.e., along a defined flow path) into the longitudinal cylinder bore 338.A ball check valve 344 is mounted in the exhaust cylinder section 334b ​​to provide movement between a closed position, in which it contacts a valve seat 348 on the exhaust cylinder section to block flow through the longitudinal axis cylinder bore 338, and an open position, in which it allows flow through the bore. A coiled compression spring 352, acting on the ball valve at one end, pushes the ball valve into its closed position. The opposite end of the spring presses against an exhaust port 354, which is screwed into the exhaust end of the cylinder bore 338. The exhaust port has a lubricant outlet port 356, which defines a cylinder outlet, and a pressure sensor port 358.

[0024] As in Fig. As shown in Figure 4, a T-connector 360 is connected to the lubricant outlet port 356 of the outlet port 354 to provide fluid flow to a first supply line 364, which is connected to the pump housing 306 at one point, and to a second supply line 366, which is attached at a second point a distance around the housing from the first point. The outlet end of each supply line 364, 366 is equipped with a quick-connect / disconnect fitting 370 to allow connection of the supply line to a lubricant supply line that provides lubricant to a distribution system of any type. Generally, only one of the two supply lines 364, 366 is used for any given distribution system, with the supply line being selected whose configuration is best suited to the field conditions.

[0025] A pressure sensor 372 is attached to the pressure sensor port 358 of the outlet port 354. The pressure sensor measures the pressure at the outlet end of the cylinder bore 338 ( Fig. 6).

[0026] What's next in Fig. As shown in Figure 6, a relief channel 376 in the pump cylinder 334 provides fluid communication between a first location in the longitudinal cylinder bore 338 upstream of the check valve seat 348 and a second location in the longitudinal cylinder bore downstream of the check valve seat. The end located downstream of the relief channel 376 communicates with the second location via a radial bore 380 in the outlet cylinder section 334a. The purpose of this relief channel 376 will become apparent below.

[0027] The pump unit 300 further comprises a piston 384, which can be moved back and forth in the cylinder bore 338 by a second drive mechanism generally designated 390. In the embodiment shown Fig. 3-9 The drive mechanism 390 is a linear position drive mechanism comprising a stepper motor 394 having an output shaft 396 rotatably mounted in a sleeve 398 in an end wall 400 of a plunger housing 404, which is attached to the lower wall of the container. The shaft 396 is drivenly connected to a leadscrew 410, and the leadscrew is screwed to a plunger 414 in the plunger housing 404. The plunger 414 and the piston 384 are fixed in a non-rotatable manner. Preferably, the plunger and the piston are designed as a single component, but they can also be designed as separate components that are fixed to one another in a non-rotatable manner. As in Fig. As shown in Figure 7, the tappet 414 has a radial sleeve 418 with notches 420 for receiving stationary, linear guides 424 on the inside of the tappet housing 404. The guides 424 extend in a direction that is generally parallel to the longitudinal axis of the cylinder bore 338 and prevent the tappet 414 (and piston 384) from rotating when the leadscrew 410 is rotated by the stepper motor 394. Thus, rotation of the motor output shaft 396 in one direction causes the piston 384 to move in a pumping (power) stroke in the cylinder bore 338, and rotation of the shaft 396 in the opposite direction causes the piston to move in a return stroke in the cylinder bore. The lengths of the strokes are controlled by the operation of the stepper motor.

[0028] A calibration mechanism that is in Fig. The mechanism 430, generally designated as 430, is provided for calibrating the operation of the stepper motor 394 relative to the position of the piston 430 in the cylinder bore 338. In the illustrated embodiment, this mechanism 430 comprises a magnet 434 on the plunger 414, which can be moved with the piston and plunger, and at least one, and preferably two, magnetic field sensors 440, 442, which are arranged on the plunger housing 404 at intervals relative to the direction of the piston movement. The sensors 440, 442 can, for example, be reed switches located near the magnet 434.

[0029] In some embodiments, one motor can be used to drive both the pump and the agitator. In other embodiments, the agitator motor 326 and the stepper motor 394 are separate, individual, independently driven motors, instead of one motor for both the agitator and the pump. One advantage of using two motors is as follows: In colder environments, the lubricant can become viscous, resulting in increased resistance to the rotation of the agitator. This increased resistance slows the rotation of the motor driving the agitator. If the motor driving the agitator also drives the pump, the slower rotation reduces the pump's operating rate and the rate at which lubricant is pumped.However, if two independently driven motors are used and the lubricant is viscous and slows down the rotation of the agitator motor, the pump motor can continue to operate independently to pump lubricant at a speed that is independent of the speed of the agitator motor.

[0030] With reference to Fig. The pump unit 300 includes a controller 450 for calibrating and controlling the operation of the linear position drive mechanism 390. The controller 450 receives signals from the pressure sensor 372 and the calibration mechanism 430 (e.g., magnetic field sensors 440, 442). The controller 450 includes a programmable microprocessor that processes information and controls the operation of the agitator motor 326 and the stepper motor 394. An operator input 454 with a display 456 is provided for inputting information into the controller and for the controller to use this information to provide information to an operator. This information can include the type of lubricant distribution system to be used with the pump unit, the volume of lubricant to be supplied to each lubrication point (e.g., bearings), and the frequency of lubrication events.In addition, information can be uploaded to and downloaded from the controller via a USB 460 port in the pump housing of the pump unit.

[0031] The pump unit 300 is powered via a power supply 462, which is usually the power supply for the equipment to be lubricated.

[0032] As already mentioned, the pump unit 300 of this invention can be used with various distribution systems. For example, the pump unit can be used with a progressive (distributor) valve distribution system 500, as shown in Fig. Figure 10 shows an injector distribution system 600, as shown in Fig. Figure 11 shows a CAN bus distribution system 700, as shown in Fig. 12 shown, double piping systems, as in Fig. 19A-19C shown, distribution systems divided into zones, as in Fig. Figures 16-19 illustrate this, and combinations of these systems are used, although this list is not exhaustive. Examples of these systems are described below.

[0033] In the progressive distribution system 500 from Fig. The pump unit 300 pumps the desired quantity of lubricant through a lubricant supply line 510 at desired intervals to a series of conventional distribution valves 530. The distribution valves operate to supply measured quantities of lubricant to the respective lubrication points 550 (e.g., bearings). Each distribution valve has a proximity switch 532, which is connected to the controller 450 to monitor the proper operation of the distribution valve. The controller 450 is programmed accordingly (e.g., via the operator input 454 and / or the USB port 460) to operate the pump unit 300 as described below.

[0034] Preferably, the controller 450 initiates the operation of the agitator motor 326 before the stepper motor 394 is operated to move the piston 384 back and forth. This sequence allows the agitator 320 to fluidize the lubricant and prepare the pump cylinder 334 with lubricant before the actual pumping of lubricant begins, which can be particularly advantageous if the lubricant is viscous, as in cold-temperature environments. After a suitable delay of a predetermined length (e.g., eight to twelve seconds), the stepper motor 394 is switched on to move the piston 384 in a sequence of pumping (power) strokes and return strokes to pump the desired quantity of lubricant through the supply line (364 or 366) connected to the distributor lubricant supply line 510.When the pump unit is operated in this mode, the downstream end of the piston 384 remains downstream of the point where the relief channel 376 communicates with the cylinder bore 338 (see . Fig. 8, which shows the piston at the maximum position of its return stroke). This prevents the lubricant supply line 510 of the distributor system 500 from being relieved into the reservoir 304 of the pump unit during the return strokes of the piston 384. Such relief is not required in a progressive (distributor) valve distributor application. A piston return stroke during which no relief occurs is referred to below as a "non-relieving" return stroke.

[0035] In the injector distribution system 600 from Fig. The control unit 450 of the pump unit 300 is programmed to operate the unit in such a way that it pumps the desired quantity of lubricant at desired time intervals through a lubricant supply line 610 to a plurality of injectors 620. The injectors provide measured quantities of lubricant to corresponding lubrication points 630 (e.g., bearings). In this mode, the pump unit 300 operates as described above, except that during its return stroke, the piston 384 moves into a relief position upstream of the point where the relief channel 376 communicates with the cylinder bore 338 (see Fig. 9, which shows the piston at the maximum position of its return stroke). This allows lubricant to be drained into reservoir 304 during the piston's return stroke so that the injectors 620 can be reset for subsequent operating circuits. A piston return stroke during which unloading occurs is referred to below as a "reloading" return stroke.

[0036] In the CAN bus and distributor valve system 700 from Fig. 12 The controller 450 of the pump unit 300 is programmed to operate the unit so that it pumps the desired quantity of lubricant through a lubricant supply line 702 to a first valve body, which includes a manifold 706 with outlets 710 connected to respective lubrication points 714 (e.g., bearings) in a first zone Z1. The fluid flow through the bores is controlled by respective electronically controlled valves 718, which receive control signals from the controller 450 via an energy fieldbus 720 and are powered to supply the valves with current. In the embodiment from Fig. In addition, lubricant is supplied via the lubricant supply line 710 to a second valve body, which includes a manifold 724 connected in series with the first manifold 706 in fluid communication. The manifold 724 has outlets 728 connected to respective lubrication points 730 (e.g., bearings) in a second zone Z2. The fluid flow through the manifold to the outlets 728 is controlled by respective electronically controlled valves 730, which receive control signals from the controller 450 via the energy fieldbus 720 and are powered to supply the valves with current.

[0037] Fig. Figures 13-15 show an exemplary valve body (manifold 706) and a plurality of exemplary electronically controlled valves (valves 718) used in the CAN bus lubrication system. Fig. 12. The manifold 706 is equipped with four such valves, but this number can vary from one to two or more. The manifold 706 comprises a block with an inlet 732 connected to the lubricant supply line 702, a supply channel 734 extending from the inlet through the manifold, and a plurality of outlet channels 738 connecting the supply channel and associated outlets 710 of the manifold. Ball check valves 742 in the outlets 710 are spring-loaded towards their closed positions to prevent backflow.

[0038] Each valve 718 comprises a valve element 746 (e.g., a movable valve tappet, as in Fig. (15 shown), which is assigned to a respective outlet 710 of the manifold 706 to control the fluid flow through the outlet. The valve element is moved back and forth between its open and closed positions by an electronically controlled actuator 750, which in this embodiment includes a cylinder coil 752. The actuator 750 also includes an electronic control circuit (ESS) 756 (e.g., a microcontroller circuit) for controlling the operation of the actuator. Each ESS is part of the CAN network that is connected to the controller 450 of the pump unit 300 and responds to CAN messages from the controller addressed to the respective ESS 756. The ESS has a control port 758 that is adapted to receive the CAN messages for the operation of the actuator 750 to move the valve element 746 back and forth between its open and closed positions.The actuator 750 has a power connection 762 for supplying power for the purpose of selectively switching on the cylinder coil 752. In one embodiment, the actuator 750 includes a switch 768 (. Fig. 15), which is controlled by the ESS and connected to power cables. The switch 768 is selectively closed by the ESS 756 to connect the external power supply via the power cables to the cylinder coil 752 (or another device), thereby moving the valve element 746 to allow fluid flow.

[0039] As in Fig. As shown in Figure 13, the energy fieldbus 720 is connected from one valve 718 to another valve 718 via suitable electrical connections 770. If the ESS requires power, it can be connected to the external power supply via the switch 768 and the power cables.

[0040] In one embodiment, the energy fieldbus 720 comprises a four-wire bus with two cables that transmit CAN messages from the communication port (KOM 772) of the controller 450 of the pump unit 300 to the electronic control circuit (ESS 756) to control the operation of the electronically operated valves 718. Two cables supply power to a respective electronically controlled actuator 750 from an external power source (e.g., 24 volts) to switch on a respective cylinder coil. The power cables can be connected to a power source of the device to be lubricated or to a separate power source. The controller 450 can be programmed by an operator, for example, via the input device 454 (e.g., keyboard or touchscreen) and / or the USB port 460, to control the operating mode.In CAN bus mode, the operator can program the controller 450 to control the operating sequence of the valves 740, the frequency of valve operation, and the amount of lubricant to be provided.

[0041] The construction and operation of the second manifold 724 and its associated electronically controlled valves 730 ( Fig. 12) are essentially identical to the above-described structure and operation of the first manifold 706 and its associated valves 718. The fluid flow through the channels in the second manifold 724 is controlled by respective electronically operated valves, which receive control signals from the control unit and current via the energy fieldbus 720 to supply the cylinder coils 752 with current.

[0042] In general, the cylinder coil valves 718, 730 of the two manifolds 706, 724 are operated by the control 450 of the pump unit 300 in a desired sequence, preferably one after the other, to supply a measured quantity of fluid (determined by the stroke of the piston) to respective lubrication points in two different zones Z1, Z2. The piston 384 of the pump unit 300 is operated such that it is moved in non-relieving return strokes, as described above with reference to the progressive distributor system 500.

[0043] In the distribution system 800 from Fig. The controller is programmed to operate the pump unit 300 in such a way that it pumps the desired quantity of lubricant through a lubricant supply line 804 to a manifold 808, which has channels that are in fluid communication with two outlets 816. The fluid flow through the channels to the respective outlets is controlled by corresponding electronically operated valves 818, which receive control signals from the controller 450 of the pump unit 300 via an energy fieldbus 820. One of the two outlets 816 is connected via a lubricant supply line 824 to a first row consisting of one or more distribution valves 830 for supplying measured quantities of lubricant to lubrication points 834 (e.g., bearings) in a first zone Z1.The other outlet 816 is connected via a lubricant supply line 840 to a second row consisting of one or more distributor valves 844 for supplying measured quantities of lubricant to lubrication points 850 (e.g., bearings) in a second zone Z2. The master distributor valve of each row of master valves 830, 844 has a proximity switch 846 connected to the controller 450 to monitor the proper operation of the distributor valve. The flow of lubricant to zones Z1, Z2 is controlled by selectively activating the electronically operated valves 818, as described in the previous embodiment ( ). Fig. 12-15). When used with this type of lubricant distribution system, the piston 384 of the pump unit 300 moves in non-relieving return strokes, as described above with reference to progressive distribution systems 500.

[0044] In the embodiment from Fig. The manifold 808 is essentially constructed in the same way as described above with reference to Fig. described in sections 13-15.

[0045] In the distribution system 900 from Fig. The controller 450 is programmed to operate the pump unit 300 to pump the required quantity of lubricant through a lubricant supply line 904 to a manifold 908, which has channels connected to two outlets 916 in fluid communication. The fluid flow through the channels to the respective outlets 916 is controlled by corresponding valves 918, which are controlled by cylinder coils and receive control signals from the controller 450 via an energy fieldbus 920. One of the two outlets 816 is connected by a lubricant supply line 924 to a first row consisting of one or more distribution valves 930 to supply measured quantities of lubricant to lubrication points 934 (e.g., bearings) in a first zone Z1. The master distributor valve of the 930 series of distributor valves has a proximity switch 932 which is connected to the control unit 450 to monitor the proper operation of the distributor valve.The other outlet 916 is connected by a lubricant supply line 940 to a second manifold 944, which has channels that communicate with outlets 946, which are connected to respective lubrication points 948 (e.g., bearings) in a second zone Z2. The fluid flow through the outlets 946 in the second manifold 944 is controlled by respective electronically operated valves 950, which receive control signals from the controller via the energy fieldbus 920. The lubricant flow to the first and second zones Z1, Z2 is controlled by selectively activating the electronically operated valves 918, 950, as in the embodiment shown in [reference]. Fig. 12-15. When used with this type of lubricant distribution system, the piston 384 of the pump unit 300 moves in non-relieving return strokes, as described above with reference to the progressive distribution system 500.

[0046] In the embodiment from Fig. 17. The manifold 808 is essentially constructed in the same way as described above with reference to Fig. described in sections 13-15.

[0047] In the distribution system 1000 from Fig. The controller 450 of the pump unit 300 is programmed to operate the unit in such a way that it pumps the desired quantity of lubricant through a lubricant supply line 1004 to a manifold 1008, which has channels that are in fluid communication with two outlets 1016. The fluid flow through the channels to the respective outlets 1016 is controlled by electronically operated valves 1018, which receive control signals from the controller 450 via an energy fieldbus 1020. One of the two outlets 1016 is connected via a lubricant supply line 1024 to a first row consisting of one or more injectors 1030, which provide measured quantities of lubricant to lubrication points 1034 (e.g., bearings) in a first zone Z1. The other outlet 1016 is connected via a lubricant supply line 1040 to a second row consisting of one or more injectors 1044, which deliver measured quantities of lubricant to lubrication points 1048 (e.g.B. bearings) in a second zone Z2. The lubricant flow to the first and second zones is controlled by the selective activation of the electronically operated valves 1018, as in the embodiment shown in . Fig. 12-15 described. When used with this type of lubricant distribution system, the piston 384 of the pump unit 300 moves in relieving return strokes, as described above with reference to the injector distribution system 600.

[0048] In the embodiment from Fig. The manifold 1008 is constructed in the same way as described above. Fig. described in 13-15, except that the check valves 742 in the outlets 1016 are omitted so that the injectors 1030, 1044 can be reset during the relieving return strokes of the piston 384.

[0049] In the distribution system 1100 from Fig. The control unit 450 of the pump unit 300 is programmed to operate the unit in such a way that it pumps the desired quantity of lubricant through a lubricant supply line 1104 to a manifold 1108, which has channels that are in fluid communication with two outlets 1116. The fluid flow through the channels to the corresponding outlets 1116 is controlled by respective electronically operated valves 1118, which receive control signals from the control unit 450 via an energy fieldbus 1120.

[0050] In one embodiment, the energy fieldbus 1120 includes a double cable. A first cable of the bus 1120 is a data cable that transmits between the controller and the CAN modules. It transmits CAN messages to control each of the CAN modules 1121 and 1123 and is connected to each module, for example, via a daisy chain. The first cable also transmits CAN messages from CAN modules to the controller (such as sensor signals). A second cable of the bus 1120 carries power to each of the CAN modules, which is used to energize the valves associated with each CAN module. The power cable is connected, for example, via a daisy chain, to relays of each CAN module that energize the valves. As in Fig. As shown in Figure 19, the CAN module 1121 has two separate sets of power lines. Each set selectively supplies power to each of the valves 1118 and is located between the module and its associated valves 1118. The CAN module 1123 has four separate sets of power lines. Each set selectively supplies power to each of the corresponding valves 1150A-1150D. As used herein, a relay includes an electrically or mechanically actuated switch and / or any other device for controlling a circuit via a low-voltage signal.

[0051] One of the two outlets 1116 is connected via a lubricant supply line 1124 to a series of injectors 1130, which supply measured quantities of lubricant to lubrication points (e.g., bearings) in a first zone Z1. The other outlet 1116 is connected via a lubricant supply line 1140 to a second manifold 1144, which has channels that communicate fluidly with respective outlets 1146, which in turn communicate with corresponding lubrication points 1148A-1148D (e.g., bearings) in a second zone Z2. The fluid flow through the channels of the second manifold 1144 is controlled by corresponding electronically operated valves 1150A-1150D, which receive control signals from the controller 450 via the first cable of the energy fieldbus 1120. The CAN module 1123 selectively and sequentially connects the valves 1150A-1150D to be lubricated to the second cable of the energy fieldbus 1120 in order to supply the valves 1150A-1150D with power. (See Fig. 36A for an exemplary sequential actuation of the valves 1150A-1150D.) The flow of lubricant to the first and second zones Z1, Z2 is controlled by the selective actuation of the electronically operated valves 1118, as in the embodiment shown in Figure 36A. Fig. Described in Figures 12-15. The CAN module 1121 selectively connects the valves 1118 to the second cable of the energy fieldbus 1120 to supply power to the valves 1118. When used with this type of lubricant distribution system, the piston 384 of the pump unit 300 moves in relief strokes when the lubricant is directed to the injectors 1130 in the first zone Z1; and the piston moves in non-relief strokes when the lubricant is directed to the second manifold 1144 in the second zone Z2.

[0052] In the embodiment from Fig. The manifold 1108 is constructed in the same way as described above with reference to Fig. as described in 13-15, except that the check valve 742 in the outlet 1116, which is connected to the injectors 1130, has been omitted so that the injectors 1130 can be reset during the relieving return strokes of the piston 384.

[0053] In the distribution system 1400 from Fig. 19A, the controller 450 of the pump unit 300 is programmed to pump a desired quantity of lubricant through a lubricant supply line 1404 to a manifold 1408, which has channels that communicate with two outlets 1416. The fluid flow through the channels to the respective outlets 1416 is controlled by corresponding electronically operated valves 1418, which receive control signals and power from the controller 450 via an energy fieldbus 1420. One of the two outlets 1416 is connected via a lubricant supply line 1424 to a series of injectors 1430, which supply measured quantities of lubricant to lubrication points 1434 (e.g., bearings) in a first zone Z1. The other outlet 1416 is connected via a lubricant supply line 1440 to a pressure inlet 1450 of a switchable four-way valve 1452.The changeover valve 1452 includes a relief port 1454, which is connected to a return line 1456 leading to a return port 1458 on the pump unit 300, which is in fluid communication with the reservoir 304. Two main lubricant lines 1470A and 1470B are connected to respective ports 1472A and 1472B of the changeover valve 1452. The main lubricant lines 1470A and 1470B supply lubricant to dual-line metering valves 1480, which provide measured quantities of lubricant to lubrication points 1482 (e.g., bearings).

[0054] The changeover valve 1452 can be set to one of two positions. In the first position, lubricant entering the pressure inlet 1450 flows through the first port 1472A of the valve 1452 to the first main lubricant line 1470A. When the changeover valve 1452 is in this first position, lubricant entering through the second port 1472B flows through the relief port 1454 to the return line 1456 and ultimately back into the reservoir 304. When the changeover valve 1452 is in the second position, lubricant entering through the pressure inlet 1450 flows through the second port 1472B of the valve 1452 to the second main lubricant line 1470B. When the changeover valve is in the second position, lubricant entering through the first port 1472A flows through the relief port 1451 to the return line 1456 and ultimately back to the reservoir 304.When valve 1452 is in its first position, lubricant is discharged under pressure into the first lubricant line 1470A, and the second lubricant line 1470B is connected to the reservoir 304. When valve 1452 is in its second position, lubricant is discharged under pressure into the second lubricant line 1470B, and the first lubricant line 1470A is connected to the reservoir 304. During operation, the changeover valve 1452 switches from the first position to the second position as described below.

[0055] When the changeover valve 1452 is in its first position, lubricant conveyed through the first lubricant line 1470A is discharged under pressure from the first side of each measuring valve 1480 to the respective lubrication points 1482. When the lubricant is discharged from the last measuring valve 1480, the pump unit 300 continues to operate, and the pressure in the first lubricant line 1470A increases until the lubricant in the line reaches a pre-selected pressure (e.g., 3000 psi). When the lubricant in line 1470A reaches the pre-selected pressure, the four-way changeover valve 1452 moves to its second position, directing lubricant through the second lubricant line 1470B and connecting the first lubricant line 1470A to the reservoir 304, thus releasing the pressure in the first line.Lubricant, conveyed through the second lubricant line 1470B, is discharged under pressure from the opposite side of each measuring valve 1480 to the corresponding lubrication points 1482. As the lubricant is discharged from the last measuring valve 1480, the pressure in the second lubricant line 1470B increases until the lubricant in the line reaches a pre-selected pressure. When the lubricant reaches the pre-selected pressure, a signal from a pressure limit switch (not shown) or a microswitch (not shown) on the changeover valve 1452 stops the pump unit 300.

[0056] In the embodiment from Fig. 19A, the manifold 1408 is constructed in the same way as above with reference to Fig. as described in 13-15, except that the check valve 742 in the outlet 1416 connected to the injectors 1430 has been omitted so that the injectors 1430 can be reset during the relieving return strokes of the piston 384.

[0057] Dual-line zones, such as zone Z2 Fig. 19A, can be combined with other dual-pipe zones (not shown) or with distribution valve zones (such as zone Z1 from Fig. 19B) combined or used individually (as in Fig. (19C shown), without deviating from the scope of the present invention. As will be apparent to those skilled in the art, double-line zones can be used effectively with long lines, at high pressure and / or for hundreds of lubrication points. In addition to the Fig. In the dead-end system shown in 19A-19C, the double-pipe zone can be configured in other double-pipe system arrangements, such as a line system or a circular system, depending on the specific application.

[0058] Preferably, each of the lubricant supply lines (e.g., 510, 610, 702, 804, 824, 840, 904, 924, 940, 1004, 1024, 1040, 1104, 1124, 1140) that convey lubricant from the pump unit 300 to the aforementioned systems comprises a hose that is substantially non-expandable when the pressure is below a predetermined limit (e.g., 1500 psi). To ensure that the correct amount of fluid is delivered from the pump unit to the lubrication points, it is desirable for the lubricant in the supply lines to remain below this limit. For this purpose, the pressure sensor 372 is provided at the outlet end of the cylinder bore 338. The controller 450 responds to signals from this sensor. If the pressure measured by sensor 372 remains below the specified limit, the controller operates the stepper motor 394 at a predetermined normal speed to pump lubricant at a predetermined rate.If the pressure measured by sensor 372 exceeds the limit value, the controller operates the stepper motor 394 at a slower speed to supply the desired amount of lubricant at a slower rate, thus preventing unwanted hose expansion and backpressure in the system, including the lubricant supply lines. In one embodiment, the hose used for the lubricant supply lines has an inner diameter of approximately 0.250 inches (approximately 0.635 cm) and a distance of up to eighty feet (approximately 24.38 m) from the pump unit 300 to a lubrication point. Preferably, the length of the lubricant supply line from the pump unit to the first bend of the lubricant distribution unit is no more than approximately fifty feet (approximately 15.24 m).

[0059] Preferably, a pump unit 300 of the distribution system 1100 is equipped with a self-diagnostic system to identify the cause of a pump failure. Lubrication systems can fail for various reasons. First, the pump components wear down to a point where they can no longer generate the pressure required to operate the lubrication system. This can be due to seal wear, piston wear, and / or cylinder wear. Second, the outlet check valve may be unable to maintain pressure by preventing backflow into the system. This can be caused by the valve seat becoming chipped and corroded, the ball becoming chipped or corroded, or a foreign object becoming lodged in the valve seat and preventing a proper seal. Third, greases can become viscous and difficult to pump when the ambient temperature decreases.At a certain point, the pressure required to move the grease becomes unbearable. A pump unit equipped with the self-diagnostic system described below can perform diagnostic tests to determine if a system failure was caused by one of the reasons mentioned above.

[0060] If the System 1100 is unable to pump lubricant properly, the self-diagnostic system performs three diagnostic tests.

[0061] To test whether the pump is capable of generating the appropriate pressure, the controller 450 signals the electronically operated valves 1118 of the manifold 1108 to close their respective bores. The stepper motor 394 is then operated by the controller 450 to move the piston 384 a small distance into the cylinder bore 338. The pressure at the outlet of the pump cylinder is measured by the pressure sensor 372. The processor of the controller 450 reads the pressure from the sensor and compares these measurements with a reference pressure or pressure values ​​to determine whether the pressure build-up is sufficient.

[0062] To test whether the check valve 344 is able to maintain the appropriate pressure, the controller 450 operates the stepper motor 394 to retract the pump piston 384 a small distance into the cylinder bore 338. The pressure at the outlet of the pump cylinder is measured by the pressure sensor 372. The controller's processor takes pressure measurements from the sensor and compares these measurements. If the pressure drops, the drop in pressure indicates a failure of the check valve 344; if the pressure is maintained, the check valve is functioning properly.

[00130] To test whether the grease is too viscous for proper operation, a user performs a test called a pressure relief gauge test, as described in U.S. Patent 7,980,118, which is incorporated herein by reference.To perform this test, the controller 450 operates the stepper motor 394 to move the piston 384 forward until the pressure measured by the pressure sensor 372 at the outlet of the cylinder bore 338 reaches a predetermined pressure (e.g., 1800 psi). The stepper motor is then operated to move the piston with a relieving stroke to its relief position, in which the grease in the lubricant supply line flows back into the reservoir. After a delay of a certain duration (e.g., 30 seconds), the pressure at the outlet of the cylinder bore 388 is recorded. The controller then uses the following equation to determine the yield stress (Y) of the grease: Y=[p π r2 / 2 π rl]=pr / 2 l

[0063] where “p” is the recorded pressure at the cylinder bore outlet after 30 seconds; “r” is the radius of the lubricant supply line 1104; and “l” is the length of the lubricant supply line 1104 from the pump unit 300 to the first elbow 1108. The values ​​of “r” and “l” are provided by the user via operator input and / or the USB connection to the controller.

[0064] If the calculated flow stress (Y) of the grease exceeds a known value at which the grease is too viscous for proper pump operation (e.g., at a value of 0.125), the 450 controller displays a warning message to the user. The warning message instructs the user to switch to a less viscous grease.

[0065] A pump unit 300, which has a self-diagnostic function as described above, can be used with any type of lubricant distribution system in which the flow through the lubricant supply line from the pump unit to the lubrication points can be blocked.

[0066] The self-diagnostic system described above can also include a test to determine the proper operation of the motor. To perform this test, the controller 450 opens an electronically operated valve 1118 to allow at least a limited flow through the lubricant distribution system. The controller then operates the stepper motor 394 to move the piston 384 in successive pumping and return strokes. The movement of the piston is measured by magnetic field sensors 440 and 442, which are mounted on the tappet housing 404. Based on the feedback from the sensors, the controller can determine whether the motor 394 moves the piston back and forth through its entire range of motion. The test can also be used to detect the existence of an unwanted binding in the drive mechanism, for example, due to misalignment of the drive components.This is determined by measuring the amount of electrical voltage drawn by motor 394 while it is operating to move piston 384. Excessive current draw (e.g., 1.0 ampere or more) may indicate an unwanted binding of the motor and / or the leadscrew mechanism. The controller continues to rotate the motor slowly (e.g., 0.75 inches in 10 seconds) during this test to avoid excessive back pressure in the system.

[0067] The self-diagnostic tests described above can be performed automatically in response to a fault signal indicating a problem with the pump unit or the lubricant distribution system. Additionally, a self-diagnostic grease stiffness test can be performed if the temperature of the lubricant in the reservoir, as measured by temperature sensor 332 ( Fig. 4) is determined to fall below a predetermined temperature.

[0068] Additional functions of a self-diagnostic system of this invention are described below in this description.

[0069] It is evident from the foregoing that a pump unit 300 of this invention offers many advantages. For example, the controller 450 is programmed to operate the pump in the following modes: (i) in a distribution valve mode in which lubricant is directed from the pump to one or more distribution valve(s) for supply to multiple lubrication points; (ii) in an injector mode in which lubricant is directed from the pump to a plurality of lubricant injectors for supply to multiple lubrication points; (iii) in a dual-line system mode in which lubricant is conveyed from the pump to a plurality of lubricant injectors for supply to multiple lubrication points, the injectors having diverter valves for draining lubricant into the reservoir; and (iv) in a CAN bus mode, (a) in which the lubricant is conveyed from the pump to a plurality of magnetically operated valves for the purpose of supplying it to several lubrication points, (b) CAN messages that control the cylinder coils are provided via the fieldbus and (c) Power to operate the cylinder coils is provided via the fieldbus.

[0070] The fact that the agitator 320 and the pump piston 384 are driven by two separate drive mechanisms also allows the agitator and the piston to be driven independently of each other. This enables the lubricant in the container to be fluidized before the stepper motor is operated to move the piston back and forth and pump the lubricant. The movement of the agitator also serves to prepare the pump by forcing lubricant through the container outlet directly (i.e., along a defined flow path) into the inlet of the pump cylinder.

[0071] The pump unit 300 is capable of pumping viscous lubricants at relatively low temperatures. This is due, at least in part, to the strong push / pull forces exerted on the lubricant to force it from the reservoir 304 directly into the cylinder bore 338. As described above, the rotation of the agitator 320 causes the pressure lubrication mechanism 330 to exert a strong downward force on the lubricant inside the reservoir 320, forcing it along a defined flow path (e.g., as in Fig. (Figure 6) is pressed into the cylinder bore 338. Furthermore, a return stroke of the piston 384 generates a force that draws the same lubricant along the same defined flow path. The combination of these pushing and pulling forces proves to be very effective for moving viscous lubricant into the cylinder bore 338 at low temperatures.

[0072] Other advantages of this invention are evident. The use of two separate drive mechanisms (one to drive the agitator and one to drive the piston), and in particular the use of a linear position motor (e.g., a stepper motor), eliminates much of the complexity of conventional pump units. The pump unit efficiently pumps lubricant over a wide temperature range. Furthermore, the various supply lines of these pump units offer greater flexibility when installing the system in the field.

[0073] Furthermore, the pump unit may include diagnostic software for performing diagnostic tests to determine one or more of the following: (i) a capability of the pump to generate a minimum pressure at the cylinder outlet; (ii) a capability of the check valve to block backflow through the outlet; (iii) whether the grease in the container is too viscous to be pumped by the pump; and (iv) the current consumption of the motor of the drive mechanism when the piston moves in the cylinder bore.

[0074] Fig. Figure 20 shows an alternative linear position drive mechanism, generally characterized by 1200, for moving the piston 384 of the pump unit 300 back and forth. The drive mechanism of this embodiment is similar to the stepper motor drive mechanism of the previous embodiment. However, the drive mechanism includes a reversible motor 1204, which is not a stepper motor. Position markers 1210 on the plunger 1214 can be read by a position sensor 1220 on the plunger housing 1224. The position sensor 1220 is connected to the control unit 1226 of the pump unit to signal the longitudinal position of the plunger 1214 and the piston 1230 attached to the plunger.The control unit 1226 operates the reversible motor 1204 to rotate the leadscrew 1240 in one direction to move the tappet and piston to a suitable distance (determined by the position sensor) by means of a pump stroke and in the opposite direction to move the tappet and piston to a suitable distance (determined by the position sensor) by means of a return stroke.

[0075] The position markers 1210 on the plunger 1214 can, for example, be raised metal segments arranged at predetermined intervals along the plunger, and the position sensor 1220 can be an inductive sensor that detects and counts the segments and sends signals to the controller. The controller 1226 monitors the linear position of the plunger and, based on this information, is able to move the piston to a distance required to dispense a desired amount of grease to the lubrication point. Alternatively, the position markers 1210 on the plunger can be segments of magnets arranged at predetermined intervals along the plunger, and the position sensor 1220 can be a magnetic field sensor that detects and counts the segments and sends signals to the controller.The control system monitors the linear position of the plunger and, based on this information, is able to move the piston to a distance required to deliver a desired amount of grease to the lubrication point.

[0076] The linear position markers 1210 and the sensor 1220 can also be used to determine when the piston 1230 is at the extreme points of its movement. This information can be used to calibrate the system. When the system is activated for the first time, it is calibrated so that the controller knows the position of the piston at the limits of its movement.

[0077] Other linear position drive mechanisms can also be used.

[0078] Fig. Figure 21 shows another embodiment of a linear position drive mechanism, generally characterized by 1300, for moving the piston of the pump unit 300 back and forth. The drive mechanism of this embodiment is similar to the drive mechanism of the previous embodiment ( Fig. 20), except that the position of the tappet 1314 and the piston 1330 is provided by a sensor device, generally characterized by 1340. The sensor device 1340 is mounted in the tappet housing 1346 and comprises a rotatable cylinder 1350, which is attached (e.g., pressed) to a surface of the leadscrew 1356, which is rotated by the motor 1370, a reversible motor but not a stepper motor. As the cylinder 1350 rotates, the sensor device 1340 monitors the angular rotation of the cylinder and signals the extent of such movement to the pump unit's controller 1380. Based on this information, the controller can determine the linear position of the piston 1330, as is evident to those skilled in the art. The control unit 1380 also controls the operation of the motor 1370 to move the piston over the appropriate distances during its pumping and return strokes.Position sensors 1380 and 1382 are provided on the plunger housing 1346 for calibrating the encoder device 1340 relative to the position of the plunger 1314 (and thus of the piston 1330). These position sensors 1380 and 1382 can, for example, be magnetic field sensors arranged on the plunger housing 1346 to detect a magnet (not shown) on the plunger, as in the stepper motor embodiment described above.

[0079] With brief reference to Fig. 37 (which is described in detail below), a system 2300 of the invention includes the pump unit described above, an alarm 2330, and sensors 2322, 2324, 2326, 2358 for measuring system conditions and providing condition signals. A controller 2308 controls the operation of the pump motor 394 by selectively switching on the motor to move the piston 384 back and forth. The controller responds to condition signals from the sensors 2322, 2324, 2326, 2358 to selectively activate the alarm when a condition signal is outside a predetermined range. In one embodiment, the controller is a processor including a tangible, computer-readable, non-volatile storage medium. The storage medium stores instructions executable by a processor for controlling the operation of the processor.In this embodiment, the processor is programmed by an operator to execute one or more sets of instructions for self-diagnosis, as in . Fig. 22-36 shown.

[0080] As used herein, a line pressure transducer (hereinafter referred to as "line DW") is any pressure sensor capable of detecting pressure in a lubricant supply line 2302, e.g. sensors 2324, 2326, 2346, 2347 and 2348 from Fig. 37 and Fig. 37A. A line-end pressure converter is a lubricant supply line pressure converter located directly upstream of the last injector of a series of one or more injectors in an injector distribution system, e.g., sensor 2347 in Fig. 37A. An internal pressure transducer or pump pressure transducer (hereinafter referred to as “internal DW” or “pump DW”) is any pressure sensor that detects pressure at the cylinder outlet of the pump unit, e.g. sensor 372 in Fig. 4, Sensor 2726 in Fig. 49 and sensor 2352 in Fig. 37 and Fig. 37A.

[0081] Fig. Figures 22-28 show flowcharts of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a closed-loop injector system and internal (pump) DW.

[0082] Fig. Figures 24-29 show flowcharts of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a non-injector system with open-loop control and internal (pump) DW.

[0083] Fig. Figures 26, 30-35 show flowcharts of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnostics for a lubrication system that has a closed-loop injector system and no internal (pump) differential pressure. In this embodiment, the stepper motor current is monitored as an indicator of the pressure.

[0084] Fig. Figures 26, 32-36 show flowcharts of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnostics for a lubrication system that has a non-injector, open-loop control system and no internal (pump) differential pressure. In this embodiment, the stepper motor current is monitored as an indicator of pressure.

[0085] Fig. Figures 22-28 show an injector system with an internal (pump) double actuation valve. The user-defined settings entered for this system include: (1) a switch-off timer setting corresponding to the maximum time between the end of one lubrication event and the start of the next lubrication event (as used herein, ‘lubrication event’ means a lubrication circuit for the injector(s) of an injector distribution system or a lubrication circuit for the distributor valve(s) of a distributor valve distribution system or a lubrication circuit for the valve(s) of a CAN bus distribution system); (2) an alarm time setting which corresponds to a maximum time from the start to the end of a lubrication event, if this time is exceeded an alarm is activated; (3) a maximum pressure setting corresponding to a maximum pressure (e.g. 3000 psi) permitted at the cylinder outlet of the pump unit as measured by the internal (pump) DW; (4) an injector activation pressure setting corresponding to a pressure (e.g. 2500 psi) as measured at a line end DW required to activate the injectors; (5) a relief pressure setting (hereinafter also referred to as the injector reset pressure setting) corresponding to a minimum pressure (e.g. 900 psi) required to reset the system's injectors; (6) a length of the lubricant supply line; and (7) a diameter of the lubricant supply line.

[0086] Fig. Figure 29 shows a distribution valve system with an internal (pump) double-acting valve. The user-defined settings for the system include a shutdown timer setting corresponding to the time between lubrication events (defined in the preceding paragraph); an alarm time setting (defined in the preceding paragraph); a maximum pressure setting (defined in the preceding paragraph); the length of the lubricant supply line; and the diameter of the lubricant supply line.

[0087] Fig. Figures 30-35 show an injector system without an internal DW. The user-defined settings include a power-off timer setting (defined above); an alarm time setting (defined above); a maximum pressure setting corresponding to a maximum pressure (e.g., 3000 psi) permissible at the cylinder outlet of the pump unit, as measured by a stepper motor current sensor; an injector activation pressure setting (defined above); and a discharge pressure setting (defined above).

[0088] Fig. Figure 36 shows a distributor valve system without an internal double-acting valve. The user-defined settings for the system include a shutdown timer setting (defined above); an alarm time setting (defined above); and a maximum pressure setting, which corresponds to a maximum pressure (e.g., 3000 psi) permissible at the cylinder outlet of the pump unit, as measured by a stepper motor current sensor.

[0089] Fig. Figure 22 is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnostics for a lubrication system that has a closed-loop injector system with internal DW. In step 1502, a shutdown timer in the processor begins counting down to the next lubrication event. In step 1504, the shutdown timer expires, and the processor switches on the agitator motor 326 to drive the agitator 320 of the pump unit 300 to stir lubricant in the reservoir 304. The agitator motor 326 is switched on for a predetermined time (e.g., 15 seconds) before the pump stepper motor 394 is switched on to begin stirring the lubricant. The agitator motor continues to run until the pump stepper motor 394 is switched off. At 1506, the processor reads the line end DW to confirm that the line pressure is below the relief pressure setting in order to reset the injectors.If the pressure is at or above the relief pressure setting, the processor executes the instructions in . Fig. 23. If the pressure falls below the relief pressure setting, the processor begins a countdown alarm at 1508, and the pump stepper motor 394 begins or continues to build pressure at 1510. At 1512, the processor displays the pressure at the cylinder outlet of the pump unit, as measured by the internal (pump) DW, on a display 456.

[0090] In 1514 in Fig. In system 22 (a closed-loop control system), the internal (pump) DW is monitored by the processor, and the speed of the stepper motor 394 is adjusted by the processor according to the lubricant pressure at the cylinder outlet of the pump unit. For example, a lookup table based on predetermined values ​​adjusts the software commands to control the speed and / or torque of the stepper motor (e.g., motor voltage, motor current, pulse operation (pulse frequency), and / or pulse force). At higher pressure, the stepper motor rotates at slower speeds.

[0091] At 1516, the processor continues with the steps in Fig. 24 to implement when the cylinder exhaust pressure has exceeded a certain maximum. In 1518, the processor continues with the steps in Fig. 25 to implement if the magnetic field sensor 442 of the pump unit 300 has not indicated that the piston is at the end of its power stroke (thus indicating an incomplete stroke). In 1520, the processor continues to execute the steps from Fig. 26 is implemented when a low-level switch of reservoir 304 is closed (indicating that the lubricant level in the reservoir is low). In 1522, the processor continues with the steps in Fig. 27 to implement if the alarm time setting is exceeded (indicating that a lubrication event is taking longer to complete than a preset period, such as 15 minutes). In 1524, the processor continues with the steps in Fig. 28 to be implemented if the stirrer motor current has exceeded a maximum current limit (indicating, for example, that the lubricant in container 304 is excessively viscous).

[0092] In 1526 in Fig. In step 22, the processor checks the internal (pump) pressure and returns to step 1510 if the internal (pump) pressure has not reached the injector activation pressure setting previously entered by the user. If the internal pressure has reached or exceeded the injector activation pressure setting, the pump stepper motor 394 is stopped by the processor in step 1528. In step 1530, the processor determines whether the alarm time setting has been exceeded. If it has, the processor implements the steps in step 1530. Fig. 27. If it has not been exceeded, the processor in 1532 determines whether the line-end pressure, measured from the line-end DW(s), has reached the injector activation pressure setting, e.g., 2500 psi. If the line-end pressure has reached the injector activation pressure setting, the processor controls the stepper motor to move the pump piston in 1534 back to its relief position (see Fig. 9) The agitator motor 326 runs in 1535 for a predetermined period (e.g., 15 seconds), and then the shutdown timer starts in 1502. If the pressure at the end of the line has not reached the injector activation pressure setting, the processor returns to 1526 to check the internal (pump) DW. If the pressure measured by the internal DW is below the injector activation pressure setting, pumping (i.e., operation of the stepper motor) continues in 1510. If the pressure measured by the internal DW reaches the injector activation pressure setting in 1526, pumping (i.e., operation of the stepper motor) stops in 1528, and the processor continues as described above.The agitator motor 326 runs in 1535 to fluidize the lubricant even after a lubrication event has ended and to prepare the lubricant in the container for the next lubrication event by preparing the pump cylinder (if necessary) with lubricant for the next lubrication event.

[0093] In Fig. 22 defines a lubrication event for a system with an agitator as the time between the end of a lubrication event in 1535 (when the predetermined operating period of the agitator motor has elapsed) and the beginning of the next lubrication event in 1504 (when the agitator motor is switched on). It is also conceivable that a system without an agitator can be operated in a similar manner to that described in Fig. 22 works. In Fig. 22 is a lubrication event for a system without a stirrer, the time between the end of a lubrication event 1534 with the return of the pump piston to its relief position and the beginning of the next lubrication event in 1510 with the switching on of the stepper motor.

[0094] Fig. Figure 23 is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide a relief (relief meter) test for a lubrication system comprising a closed-loop injector system with internal DW. From 1506 Fig. 22, as indicated in 1540, is the pressure measured at the line end DW(s) at the start of a lubrication event above the user-entered relief pressure setting. In 1542, the processor begins the relief gauge test (described above in this description) by reversing the pump stepper motor 394 and moving the pump piston 384 back to its relief position in 1544. The lubrication event then restarts, and the pump stepper motor 394 is operated to build up the internal pressure to a predetermined level (e.g., 1800 psi). The processor reverses the motor to move the piston back to the relief position, waits a predetermined time (e.g., 30 seconds), and then reads the internal (pump) DW in 1566. Using the pressure measurement of the internal (pump) differential pressure, the supply line length and the supply line diameter, the flow stress of the lubricant (e.g.B. Fetts). The test results are then compared with a predetermined yield stress level (e.g., 1000 Pa) at 1570.

[0095] If the flow stress determined in 1570 is below the predetermined level (e.g., 1000 Pa), the processor displays the positive (existing) relief gauge test results on display 456 in 1572. In 1574, the processor terminates all further timed lubrication events and activates an alarm. Display 456 indicates both a failure of the relief at the end of the lubricant supply line and the positive results of the relief gauge test. Based on this information, it can be assumed that the line-end DW pressure measurement is above the relief pressure setting due to a problem other than excessive lubricant stiffness.

[0096] However, if the flow stress determined by the relief gauge test in 1570 is higher than the preset level (e.g., 1000 Pa), the processor displays the negative (failed) relief gauge test result on display 456 in 1576. In 1578, the processor terminates all further time-controlled lubrication events and activates the alarm. Display 456 indicates a relief failure at the end of the lubricant supply line and that the lubricant (e.g., grease) has failed the relief gauge test. This result shows that the pressure measurement at the last DW of the line in 1506 is above the relief pressure setting due to excessive lubricant stiffness.

[0097] Fig. Figure 24 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a maximum pressure test for a lubrication system comprising either a closed-loop injector system with internal (pump) DW or a non-injector system with open-loop control and internal (pump) DW. As shown in Figure 1580, from Figure 1516 Fig. 22 and Fig. 29. The maximum pressure setting at the pump cylinder outlet is exceeded. In 1582, the stepper motor is immediately stopped by the processor and reversed to move the pump piston back to the relief position. In 1584, a lubrication event is initiated as soon as the pressure has been released. If the maximum pressure setting at the pump cylinder outlet is exceeded a second time in 1586, the processor switches off the stepper motor in 1588, and no further lubrication events occur. The pressure alarm is activated, and indicator 456 shows a blocked supply line. If the maximum pressure setting is not exceeded, the processor returns to 1502 in 1586 to begin a normal lubrication event, and the shutdown timer begins to count down.

[0098] Fig. Figure 25 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to perform a full-stroke test of a piston for a lubrication system comprising either a closed-loop injector system with internal (pump) DW or a non-injector system with open-loop control and internal (pump) DW. As shown in Figure 1590, the forward magnetic sensor 442 (e.g., a reed switch) was derived from Figure 1518. Fig. 22 and Fig. 29 did not close during pump stepper motor operation when stepper motor 394 was reversed for the return stroke (indicating that stepper motor 394 did not move the piston to its forward position as detected by forward sensor 442). In 1592, the processor determines if this is the second time the forward reed switch has not closed during a lubrication event or a predetermined period. If so, in 1594, the processor uses the last pressure measurement of the internal (pump) DW to adjust the stepper motor operation. For example, if the stepper motor is operated according to a profile, as with reference to Fig. As shown and described in 56-58 (below), the processor then uses the last internal (pump) DW pressure measurement to adjust the stepper motor operation to a slower speed according to a lookup table. At 1596, the processor moves the piston to its relief position, and the processor then returns to 1510 ( Fig. 22 for injector systems and Fig. 29 for distributor valve systems) to initiate another lubrication event. If the forward reed switch in 1598 fails to close again, the pump stepper motor in 1600 is switched off and the processor terminates all further timed lubrication events. Additionally, a pressure alarm is activated by the processor and indicator 456 shows that the forward reed switch has not closed. If the forward reed switch in 1598 has not failed, the processor returns to 1502 ( Fig. 22 for injector systems and Fig. 29 for distributor valve systems) and starts the shutdown timer for the next event since a normal lubrication event occurred. If the forward reed switch in 1592 has not failed a second time, the processor moves the piston in 1602 back to its relief position and implements the activity under 1510 ( Fig. 22 for injector systems and Fig. 29 for distributor valve systems) to initiate another lubrication event. If the forward reed switch in 1604 fails to close again, the processor returns to 1592. Otherwise, the processor returns to 1502 ( Fig. 22 for injector systems and Fig. 29 for distributor valve systems) to restart the shutdown timer for the next event since a normal lubrication event occurred. In one embodiment, the reed switch is a piston sensor that provides a piston signal indicating the position or movement of the piston.

[0099] Fig. Figure 26 is a flowchart of an embodiment of the invention with instructions for execution by a processor to provide a reservoir level test for a lubrication system comprising a closed-loop injector system or an open-loop non-injector system, each with or without an internal (pump) double-acting resistor. As shown in Figure 1606, the low-level reservoir switch can be derived from Figure 1520. Fig. 22, Fig. 29, Fig. 30 and Fig. 36 during pump operation. If this is the case, the processor waits until the lubrication event is complete and the pump stepper motor 394 is switched off. If the user has configured the software operating the processor to allow additional lubrication events when the low-level switch is closed, the processor proceeds from 1608 to 1610 to display a low-level alarm on a display 456. In 1613, the pump piston returns to the relief position and relieves the pressure. The processor proceeds to 1502 ( Fig. 22 for injector systems with internal DW; Fig. 29 for distribution valve systems with internal double-acting; Fig. 30 for injector systems without internal DW; Fig. 36 for distributor valve systems without internal DW), to start the shutdown timer until the next lubrication event. If the user has not configured the software operating the processor to allow additional lubrication events when the low-level switch is closed, the processor continues from 1608 to 1614. The pump stepper motor does not restart until the reservoir has been refilled. The processor displays a low-level alarm on display 456 and a low-level alarm relay is activated. When the reservoir has been refilled, the processor continues from 1510 ( Fig. 22 for injector systems with internal DW; Fig. 29 for distribution valve systems with internal double-acting; Fig. 30 for injector systems without internal DW; Fig. 36 for distributor valve systems without internal DW) continued.

[0100] Fig. Figure 27 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a cycle (i.e., injector reset) run-through test for a lubrication system comprising either a closed-loop injector system with internal (pump) DW or a non-injector system with open-loop control and internal (pump) DW. Fig. 22 and Fig. As indicated in 1620, the alarm time was exceeded in 1524 or 1530. In response, the processor initiates an outlet check test in 1622 to determine whether the outlet check valve and / or check valve seat are functioning correctly or are defective. The piston of pump unit 300 is moved back to the relief position in 1624. After relief, the pump stepper motor 394 is started and builds up pressure. The pump stepper motor 394 is stopped by the processor when the pressure measured by the power end DW 2346 equals or exceeds a predetermined setting (e.g., 1000 psi), which may have been previously entered or adjusted by the user. In 1626, the pump piston 384 is moved back to the start (relief) position, and the processor waits a specified period of time (e.g., 20 seconds). In 1628, the processor determines whether the pressure, as measured by the line end DW 2346, exceeds a certain amount (e.g.,B. 500 psi). If so, no further time-controlled lubrication events are initiated by the processor in 1630. The processor activates a pressure alarm and controls the indicator 456 to show that the alarm time setting has been exceeded due to a defective outlet check valve 344 and / or check valve seat 348.

[0101] If the pressure falls below the set value, the processor proceeds to 1632 and initiates a relief pressure test (described above). In 1634, the pump piston is moved back to the relief position, and the processor operates the pump stepper motor to build up the internal pressure to a specified value (e.g., 1800 psi) and then shuts off the pump stepper motor. In 1636, the pump piston 384 is moved back to the relief position, and the processor waits a specified period (e.g., 30 seconds) to measure the internal pump pressure. The processor then concludes by using the internal (pump) DW pressure measurement in 1638, the supply line length, and the supply line diameter to determine the grease flow stress. If the determined flow stress in 1640 is higher than the predetermined flow stress level (e.g. 1000 pa), the processor displays the negative (failed) unloading meter test result in 1642 on display 456.In 1644, the processor terminates all further time-controlled lubrication events and activates the alarm. If the determined flow stress in 1640 is less than the predetermined flow stress level (e.g., 1000 Pa), the processor displays the positive (existing) relief meter test result on display 456 in 1646. In 1648, the processor increases the alarm time setting by a predetermined amount (e.g., 50%) and initiates the alarm in 1508. Fig. 22 for injector systems and Fig. 29 for distributor valve systems) a lubrication event. If the increased alarm time setting in 1650 is not exceeded, a normal lubrication event occurred, and the processor continues to 1502. Optionally, the next and subsequent lubrication events in 1654 are monitored by the processor to determine if the alarm setting can be adjusted back to the original user setting. If the increased alarm time setting in 1650 is exceeded, and the processor determines in 1656 that this is not the second time the alarm time setting has been increased, the processor returns to 1648. If it is the second time, the processor continues to 1658. The processor will no longer initiate any further timed lubrication events, and an alarm will be triggered. Display 456 indicates that the alarm time has been exceeded.

[0102] Fig. Figure 28 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a reservoir lubricant stiffness test for a lubrication system comprising either a closed-loop injector system with internal (pump) DW or a non-injector system with open-loop control and internal (pump) DW. Fig. 22 and Fig. 29, as shown in 1660, the stirrer motor 326 exceeded its maximum current limit in 1626, so the stirrer motor is immediately stopped in 1662 and a load-sensing test is performed in 1664 and the stirrer motor is switched off. The processor returns to 1544 in Fig. 23 returns to perform a relief gauge test, whereby the pump piston returns to its relief position and the pump stepper motor is activated to build up the internal pressure at the pump cylinder outlet to the predetermined setting (e.g., 1800 psi). Alternatively or additionally to performing a relief gauge test in 1664, the processor can activate a heater to warm the lubricant. For example, a heater in the pump housing of the pump unit, in the reservoir of the pump unit, or a heating element connected to a lubricant line can be activated to reduce lubricant stiffness. As described below, stiff lubricant can be dispensed by overriding the stepper motor for a period of time. In one embodiment, a heater can be activated and the stepper motor overridden to dispense viscous lubricant.When the lubricant in the container has warmed up, the stirrer motor, which was stopped in 1662, can be switched on again, because the lubricant in the container has warmed up and its viscosity has decreased.

[0103] Fig. Figure 29 is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a non-injector (e.g. distributor valve) system with open control loop and an internal (pump) DW. Fig. 29 is identical to Fig. 22, except that 1506 is bypassed and 1526-1532 are replaced by 1702-1704. In distribution valve systems such as those found in Fig. As shown in Figure 29, at least one distribution valve (e.g., a master distribution valve) includes a proximity switch, such as an induction switch, which is set when the distribution valve moves to fill with lubricant and is reset (i.e., the switch is activated) when the distribution valve moves to empty and discharge the lubricant. In 1702, the processor acknowledges that the distribution valve's proximity switch has not been activated, indicating that the valve has not yet discharged any lubricant, and proceeds to operate the pump stepper motor 394 in 1510. If the proximity switch has been activated, the pump stepper motor stops in 1704, and the piston 384 is moved back to its starting position in 1533 (e.g., a non-relieving starting position, see Figure 29). Fig. 8) The stirrer motor 326 runs for a predetermined period (e.g. 15 seconds) in 1535 and then the switch-off timer starts again in 1502.

[0104] In Fig. 29 defines a lubrication event for a system with an agitator as the time between the end of a lubrication event in 1535 (when the predetermined operating period of the agitator motor has elapsed) and the beginning of the next lubrication event in 1504 (when the agitator motor is switched on). It is also conceivable that the system may not have an agitator and may operate in a similar manner to that described in Fig. 29. In Fig. 29 is a lubrication event for a system without a stirrer, the time between the end of a lubrication event in 1533 with the return of the pump piston to its starting position and the beginning of the next lubrication event in 1510 with the switching on of the stepper motor.

[0105] Fig. Figure 30 is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnosis for a lubrication system which has a closed-loop injector system and no internal (pump) double actuation. Fig. 30 is identical to Fig. 22, except that 1506 with Fig. 31 instead Fig. 23 is linked, 1512-1514 were replaced by 1802, 1516 was replaced by 1803, 1518, 1522, 1524 with Fig. 33, Fig. 35, Fig. 36 instead Fig. 25, Fig. 27, Fig. 28 are linked and 1526-1532 have been replaced by 1804-1806. After the pump stepper motor 394 begins or continues to build up pressure in 1510, the processor in 1802 monitors the current applied to the stepper motor, and the motor speed is adjusted according to the motor current. The applied current indicates the internal (pump) pressure at the cylinder outlet of the pump unit. The processor uses a lookup table based on predetermined values ​​to control the motor, for example, by adjusting the stepper motor voltage, adjusting the available stepper motor current, adjusting the applied current, and adjusting the pulse width modulated pulses of the operating circuit applied to the motor to control and regulate the internal (pump) pressure. At higher motor currents, the stepper motor rotates at slower speeds.In 1804, if the DW at the line end indicates that the pressure at the line end has reached the injector activation pressure setting required to activate the injectors, the pump stepper motor is stopped in 1806 and the processor continues to 1534. Otherwise, the pump stepper motor continues operation and the processor continues to 1510.

[0106] In Fig. 30 is a lubrication event for a system with an agitator. The time between the end of a lubrication event in 1535, coinciding with the expiration of the predetermined operating period of the agitator motor, and the beginning of the next lubrication event in 1504, coinciding with the switching on of the agitator motor, is defined as the time between the end of a lubrication event in 1535, coinciding with the switching on of the agitator motor. It is also conceivable that a system may not have an agitator and operate in a similar manner to that described in Fig. 30. In Fig. 30 is a lubrication event for a system without a stirrer, the time between the end of a lubrication event in 1534 with the return of the pump piston to its relief position and the beginning of the next lubrication event in 1510 with the switching on of the stepper motor.

[0107] Fig. Figure 31 is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to perform a relief meter test for a lubrication system comprising a closed-loop injector system without internal (pump) double actuation. (Figure 1506 from...) Fig. At step 30, the processor determines that the pressure measurement from the end DW is below the relief pressure setting, so the processor... Fig. 31 continues. In Fig. 31. If the pressure measurement from the end DW at the start of the lubrication event is above the user-defined relief pressure setting, the processor in 1812 will not perform any further time-controlled lubrication events. The processor activates the alarm and controls display 456 to indicate a failure of relief at the end of the lubricant supply line.

[0108] Fig. Figure 32 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a maximum pressure test for a lubrication system comprising either a closed-loop injector system without internal (pump) double actuation or a non-injector system with open-loop control and without internal (pump) double actuation. From 1803 Fig. 30 and Fig. As shown in 1814, the maximum stepper motor current driving the pump stepper motor has been exceeded. In 1816, the processor immediately stops the stepper motor and reverses it to return the pump piston to its relief position. In 1818, a lubrication event is initiated as soon as the pressure is relieved. In 1820, the processor shuts off the stepper motor in 1822 if the maximum motor current has been exceeded for the second time, and no further lubrication events occur. The pressure alarm relay is activated, and indicator 456 shows a blocked supply line. If the maximum motor current is not exceeded in 1820, the processor returns to 1502 in 1820. Fig. 30 for injector systems and Fig. 36 for distributor valve systems), to start a normal lubrication event and the shutdown timer starts counting down.

[0109] Fig. Figure 33 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a full stroke test for a piston of a lubrication system comprising either a closed-loop injector system without internal (pump) double actuation or a non-injector system with open-loop control and without internal (pump) double actuation. Fig. 33 is identical to Fig. 25, except that 1594 has been replaced by step 1824, in which the last stepper motor current measurement is used to adjust the motor to the slowest speed as specified by a lookup table. Fig. 33 departs from Fig. 30 and Fig. 36 in 1518. If the reed switch fails to close again in 1598 or 1604, the processor returns to 1502 ( Fig. 30 for injector systems and Fig. 36 for distribution valve systems).

[0110] Fig. Figure 34 is a flowchart of an embodiment of the invention and instructions for execution by a processor to provide a cycle (i.e., injector reset) run-through test for a lubrication system comprising either a closed-loop injector system without internal (pump) DW or a non-injector system with open-loop control and without internal (pump) DW. Fig. 34 is identical to Fig. 27, except that 1622-1646 were omitted. Fig. 34 departs from Fig. 30 and Fig. 36 in 1522. After the alarm time was increased in 1648, the processor reverts to 1508 ( Fig. 30 for injector systems and Fig. 36 for distribution valve systems) or the processor returns to 1502 ( Fig. 30 for injector systems and Fig. 36 for distribution valve systems) or the alarm is activated in 1658.

[0111] Fig. Figure 35 is a flowchart of an embodiment of the invention comprising instructions for execution by a processor to provide a stiffness test for lubricant in the reservoir of a lubrication system comprising either a closed-loop injector system without internal (pump) double-acting or a non-injector system with open-loop control and without internal (pump) double-acting. From 1524 Fig. 30 and Fig. As indicated in 1840, the agitator motor 326 has exceeded its maximum current limit. In 1842, the agitator motor is stopped, and in 1844, the processor terminates all timed lubrication events. An alarm is triggered, and display 456 indicates excessive agitator motor current.

[0112] Fig. Figure 36 is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnosis for a lubrication system comprising a non-injector (distributor valve) system with open control loop and without internal (pump) double actuation. Fig. 36 is identical to Fig. 30, except that 1872 replaces step 1804. In 1802, the current applied to the stepper motor is monitored in an open-loop system, and the motor speed is adjusted by the processor according to the motor current to control or adjust the internal pressure or pump pressure. A lookup table based on predetermined values ​​adjusts the stepper motor voltage, the available motor current, and the software commands to the motor. At higher motor currents, the stepper motor operates at lower speeds. In 1872, the processor confirms that the proximity switch monitoring a distribution valve in the system has not been activated, indicating that the distribution valve has not been reset, and it continues operating the pump in 1510. If the proximity switch has been activated, the pump stepper motor is turned off in 1806, and the piston is returned to its (non-relieving) starting position in 1533.

[0113] In Fig. 36 defines a lubrication event for a system with an agitator as the time between the end of a lubrication event in 1535 (at the end of the predetermined operating period of the agitator motor) and the beginning of the next lubrication event in 1504 (at the start-up of the agitator motor). It is also conceivable that a system may not have an agitator and may operate in a similar manner to that described in Fig. 36. In Fig. 36 is a lubrication event for a system without a stirrer, the time between the end of a lubrication event under 1533 with the return of the pump piston to its starting position and the beginning of the next lubrication event under 1510 with the switching on of the stepper motor.

[0114] Fig. Figure 36A is a flowchart of an embodiment of the invention consisting of instructions for execution by a processor to provide self-diagnostics for a CAN bus lubrication system having control valves without an internal pressure transducer, as shown in Fig. 19 shown. Fig. 36A is identical to Fig. 36, except that steps 1508 and 1522, which relate to the alarm timer, and step 1872, which relates to the proximity switch, are eliminated, since the system, unlike the system from Fig. 36 has no distribution valves. Therefore, there is no alarm time setting that corresponds to a maximum time from the start to the end of a lubrication event. In this system, a lubrication event involves opening a control valve for a predetermined period (or for a predetermined number of pump strokes or a predetermined number of stepper motor revolutions) to deliver a predetermined quantity of lubricant through the open valve to the respective lubrication point.

[0115] As an example of operating a system according to Fig. 36A refers to Fig. Example 19 is taken. In this example, it is assumed that bearings 1148A and 1148B are scheduled to receive a quantity of lubricant requiring 30 seconds of stepper motor operation, and that bearing 1148D is scheduled to receive a quantity of lubricant requiring 45 seconds of stepper motor operation. No lubrication is planned for bearing 1148C in this example. At 1830, the right valve 1118, which is the zone cylinder coil for zone Z2, is switched on (opened) via the CAN module 1121. At 1831, the first valve 1150A, which is linked to bearing 1148A scheduled for lubrication, is switched on (opened), and the pump stepper motor is switched on at 1510. In step 1831, the processor determines whether the volume of lubricant output by the pump corresponds to the user-programmed value for bearing 1148A (e.g., 30 seconds). If not, the pump stepper motor continues operation.If valve 1150A is open for 30 seconds (or for a predetermined number of pump strokes or a predetermined number of stepper motor rotations), the processor advances from 1832 to 1833. Since valve 1150A is not the last valve in zone Z2 scheduled for lubrication, the processor advances to 1831 to sequentially close valve 1150A and open valve 1150B. If valve 1150B is open for 30 seconds (or for a predetermined number of pump strokes or a predetermined number of stepper motor rotations), the processor advances from 1832 to 1833. Since valve 1150B is not the last valve in zone Z2 scheduled for lubrication, processor 1831 continues to sequentially close valve 1150B and open valve 1150D.If valve 1150D is open for 45 seconds (or for a predetermined number of pump strokes or a predetermined number of stepper motor rotations), the processor advances from 1832 to 1833. Since valve 1150D is the last valve in zone Z2 scheduled for lubrication, the processor advances to 1834 to stop the pump stepper motor and then to 1835 to close valves 1150D and the right-hand valve 1118, which is the zone cylinder coil for zone Z2.

[0116] In Fig. 36A is a lubrication event for a system with an agitator. The time between the end of a lubrication event in 1535, coinciding with the expiration of the predetermined operating period of the agitator motor, and the beginning of the next lubrication event in 1504, coinciding with the switching on of the agitator motor, is defined as the time between the end of a lubrication event in 1535, coinciding with the expiration of the predetermined operating period of the agitator motor, and the beginning of the next lubrication event in 1504, coinciding with the switching on of the agitator motor. It is also conceivable that a system may not have an agitator and may function in a similar manner to that described in Fig. 36A. In Fig. 36A is a lubrication event for a system without agitators, the time between the end of a lubrication event under 1533 with the return of the pump piston to its starting position and the beginning of the next lubrication event under 1510 with the switching on of the stepper motor.

[0117] As in Fig. As shown in Figures 22-37A, embodiments of the system of the invention include the controller 2308, such as a processor, and furthermore a tangible, computer-readable, non-volatile storage medium containing processor-executable instructions. The processor executes the instructions, and the instructions include at least one or more of: (i) Instructions to determine whether a lubricant injector connected to the system is relieving and to activate the alarm if the relieving gauge test indicates that the injector is not relieving ( Fig. 23 and Fig. 31); (ii) Instructions for determining a lubricant pressure at the pump and for activating the alarm when the determined pressure is greater than a maximum pressure ( Fig. 24 and Fig. 32); (iii) Instructions to determine a piston movement and to activate the alarm if the determined piston movement is less than a minimum movement ( Fig. 25 and Fig. 33); (iv) Instructions for determining the lubricant level of the container and for activating the alarm when the determined lubricant level falls below a specified minimum level ( Fig. 26); (v) Instructions for determining a lubricant pressure and for activating the alarm when the determined pressure falls below a maximum pressure after a certain period of motor pump operation ( Fig. 27 and Fig. 35); (vi) Instructions to monitor the current applied to the stirrer motor and to shut off the operation of the stirrer motor when the stirrer motor current exceeds a maximum ( Fig. 28); and (vii) Instructions for monitoring the current applied to the stirrer motor 326 and for activating the alarm when the stirrer motor current exceeds a maximum ( Fig. 35).

[0118] Fig. Figure 37 is a block diagram of an embodiment of a CAN bus lubrication system 2300 of the invention for supplying lubricant to zones of actuator-controlled valves. The lubrication system 2300 includes a pump unit 300, which has the components described above. The reservoir 304 of the pump unit receives lubricant (e.g., grease) and has a reservoir outlet 316 for supplying the lubricant to the lubricant supply system via a lubricant supply line 2302, which communicates with the cylinder outlet 354 of the pump unit. The pump unit 300 includes the cylinder 334, which defines the cylinder bore 338, the cylinder inlet 334a, which communicates with the reservoir outlet 316 to provide a flow of lubricant from the reservoir 304 into the cylinder bore 338, the cylinder outlet 354, and the piston 384, which is movably arranged in the cylinder bore 338 (see Figure 37). Fig. 3-9). The supply line 2302 includes a plurality of valves 2304, each for controlling the supply of lubricant to lubrication points, such as the bearings 2306, when the valves are open and the lubricant is under pressure generated by the pump unit 300. The drive mechanism of the pump unit (e.g., 326, 390, 1200), including the motor, such as a stepper motor 394, moves the piston 384 back and forth in the cylinder bore 338 to pressurize the lubricant. A controller 2308, such as a microprocessor and / or a programmable logic circuit, controls the operation of the motor 394 by selectively switching on the motor to move the piston 384 back and forth.

[0119] A CAN (Controller Area Network) bus 2310, in Fig. 37, represented by the dashed line, is connected to the controller 2308 and transmits CAN command signals. The CAN bus is intended to be implemented as a wired or wireless network. As used herein, the term "connect" refers to a wired or wireless connection. A power bus 2312 is connected to a power supply 2314 to provide power to the components of the system 2300, as described herein. A plurality of actuators, such as cylinder coils 2316, are linked to the valves 2304 to open or close the respective valves. A plurality of CAN modules 2320, each equipped with relays 2318, control the operation of the cylinder coils 2316. For example, each CAN module can be a slave interface with model number EZ221-CO in combination with a relay unit with model number EZ500 / 700, both of which are distributed by Eaton Corp.The slave interface connects to the CAN bus 2310 to receive CAN command signals from the controller. The relays 2318 are connected to the power bus 2312 to selectively switch on the respective actuators 2316, which in turn open and close the valves 2304 linked to the actuators to dispense lubricant. The CAN modules 2320 are connected between the CAN bus 2310 and associated relays 2318 to control corresponding relays in response to CAN command instructions provided by the controller 2310 via the CAN bus 2310.

[0120] In one embodiment, a sensor, such as a flow meter, bearing sensor, acoustic vibration sensor, thermal sensor, and / or pressure sensor, can be used to detect a condition with respect to the system 2300. In general, the sensor can be any sensor that detects lubricant, lubricant flow, a lubricant parameter, a lubricant condition, or a lubricant requirement. For example, an acoustic sensor, vibration sensor, or pressure sensor 2322 can communicate with the bearing 2306A; a pressure sensor 2324 can communicate with the lubricant supply line 2302; and / or a flow sensor 2326 can communicate with the lubricant supply line to the bearing 2306B. In each embodiment, the sensor provides a condition signal (e.g.,A pressure signal, a flow signal, a heat signal, a vibration signal) is provided, which indicates the condition it is measuring to one of the CAN modules 2320, which in turn provides a corresponding condition signal to the controller 2308 via the CAN bus 2310. The controller then reacts to the corresponding condition signal by controlling the motor 394. In one embodiment, the controller 2308 reacts to one or more condition signals by sending CAN signals via the CAN bus 2310 to at least one or more CAN modules 2310 to control the CAN relays 2318 connected to the CAN bus 2310. These relays selectively energize the cylinder coils 2316 of the CAN relays 2318 connected to the CAN modules to implement a lubrication event. This provides a system with on-demand lubrication. For example, the sensors can detect a condition of the system that corresponds to a need for a lubrication event.In particular, the sensors can detect a bearing's temperature, an acoustic output from a bearing, and / or a bearing's vibration. In response, the controller regulates the operation of the stepper motor 394 by selectively activating the motor to move the piston 384 back and forth. Thus, the controller 2308 responds to the condition signal by modifying system operation, such as selectively activating the drive mechanism and pumping lubricant when the condition signal indicates a need for lubrication, thereby providing on-demand lubrication.

[0121] In one embodiment, one or more alarms 2330 can be part of the system 2300. In this embodiment, the controller 2308 includes a memory for storing alarm conditions and responds to the condition signals by modifying the system operation, such as by selectively activating the alarm(s) 2330 when the condition signal corresponds to one of the alarm conditions. The alarm can be a visual cue, an audible cue, a message on a screen, an email, a text message, a voice message, or any other type of notification to alert an operator.

[0122] In Fig. 37 may include one or more of the zone metering valves (not shown) configured to dispense a predetermined volume of lubricant during each lubrication event. The distribution valves listed herein (see Fig. Figure 37A) is an example of measuring valves. Depending on the type of measuring valve, separate actuators (e.g., cylinder coils 2316) may or may not be required for the valves. For embodiments that include a zone with measuring valves, the controller 2308 is programmed to operate the stepper motor 394 to pump lubricant to fill the measuring valves in the zone, whereupon the measuring valves deliver measured volumes of lubricant to the bearings 2306. Alternatively or additionally, one or more of the zone(s) may include non-measuring valves 2304, which are opened and closed by their respective cylinder coils 2316. Thus, the controller controls the non-measuring valves in the zone and determines the amount of lubricant delivered during a lubrication event.For embodiments that include a zone of non-measuring valves, the controller is programmed to operate the stepper motor, pump lubricant, and deliver a predetermined volume of lubricant into the zone. Thus, the pump stepper motor 394, operated by the controller, determines the amount of lubricant delivered during a lubrication event.

[0123] The 2308 controller can be programmed to pump a predetermined volume of lubricant over a specific time period or for a certain number of pump strokes. For example, the controller can operate the pump stepper motor to deliver a predetermined volume based on the operating time of the pump stepper motor 394 (e.g., the predetermined volume is equal to the number of minutes the pump stepper motor 394 operates). 3 / min or the specified volume is equal to the minutes of operation of the pump stepper motor 394 times cc / min) to deliver the specified volume of lubricant. Alternatively, the controller can control the pump stepper motor 394 to deliver a specified volume based on a number of pump strokes (e.g., the volume is equal to the number of piston strokes times the volume of the cylinder bore displaced by the piston movement in each pump stroke, or the volume is equal to the number of strokes times the diameter of the cylinder bore times the length of each piston stroke) to deliver the specified volume of lubricant. This type of specified volume control is particularly suitable for on-demand lubrication systems and distributor valve distribution systems.In one embodiment, a user can input a predetermined volume of lubricant via the input device 454. This volume is then pumped either manually, initiated by the user, or automatically, by the processor at regular intervals for each lubrication event. In response, the controller activates the pump motor 394 for a duration corresponding to the predetermined volume. Although this type of predetermined volume control does not require sensors such as pressure or volume sensors, it is provided that in certain embodiments, sensors can optionally be used to confirm that the predetermined volume of lubricant has been pumped.

[0124] For example, the controller can be 450 in Fig. 19. Send a message to CAN module 1121 to open zone Z1 by opening the left valve 1118, whereupon the controller 450 can operate the stepper motor 394 of the pump unit 300 for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1134. Alternatively, the controller 450 can send a message to CAN module 1121 to open zone Z2 by opening the right valve 1118, whereupon the controller 450 can operate the pump stepper motor for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1148A-1148D. Other zones can be opened in a similar manner to pump a predetermined volume of lubricant.

[0125] Similarly, the 450 controller can be used in Fig. 16. Send a message to a CAN module (not shown) to open zone Z1 by opening the left valve 818, whereupon the controller 450 can operate the pump for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 834. Alternatively, the controller 450 can send a message to the CAN module to open zone Z2 by opening the right valve 818, whereupon the controller 450 can operate the pump stepper motor for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 850. Other zones can be opened in a similar manner to pump a predetermined volume of lubricant.

[0126] Similarly, the 450 controller can be used in Fig. 17. Send a message to a CAN module (not shown) to open zone Z1 by opening the left valve 918, whereupon the controller 450 can operate the pump for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 934. Alternatively, the controller 450 can send a message to the CAN module to open zone Z2 by opening the right valve 918, whereupon the controller 450 can operate the pump stepper motor for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 948. Other zones can be opened in a similar manner to pump a predetermined volume of lubricant.

[0127] Similarly, the 450 controller can be used in Fig. 18. Send a message to a CAN module (not shown) to open zone Z1 by opening the left valve 1018, whereupon the controller 450 can operate the pump for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1034. Alternatively, the controller 450 can send a message to the CAN module to open zone Z2 by opening the right valve 1018, whereupon the controller 450 can operate the pump stepper motor for a predetermined time period or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1048. Other zones can be opened in a similar manner to pump a predetermined volume of lubricant.

[0128] Similarly, the 450 controller can be used in Fig. 19A sends a message to a CAN module (not shown) to open zone Z2 by opening the left valve 1418, whereupon the controller 450 can operate the pump for a predetermined time or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1482. Alternatively, the controller 450 can send a message to the CAN module to open zone Z2 by opening the right valve 1418, whereupon the controller 450 can operate the pump stepper motor for a predetermined time or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1434. Other zones can be opened in a similar manner to pump a predetermined volume of lubricant.

[0129] Similarly, the 450 controller can be used in Fig. 19B can send a message to a CAN module (not shown) to open zone Z1 by opening the right valve 1418, whereupon the controller 450 can operate the pump for a predetermined time or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1934. Alternatively, the controller 450 can send a message to the CAN module to open zone Z2 by opening the right valve 1418, whereupon the controller 450 can operate the pump stepper motor for a predetermined time or a predetermined number of strokes to pump a corresponding predetermined volume of lubricant to the lubrication points 1482. Other zones can be opened in a similar manner to pump a predetermined volume of lubricant.

[0130] The zone from Fig. 37 and Fig. 37A can be opened in a similar manner to pump a predetermined volume of lubricant. Since the processor also knows the volume of lubricant delivered by the pump unit, this information can be used for diagnostic purposes. Consider, for example, a system with 100 lubrication points that require a total volume of 150 cc of lubricant during a lubrication event. After a lubrication event, the processor can compare the actual volume of lubricant delivered during the event with the required total volume. If the actual volume delivered is less than the required total volume, this indicates a blocked line or other problem preventing the lubricant from being delivered.If the actual volume dispensed is greater than the total required volume, this indicates a damaged line or another problem, such as a leak, causing lubricant to escape from the system. The volume of lubricant dispensed can be monitored, and an alarm can be triggered if the actual volume dispensed deviates from the total required volume.

[0131] The duration a valve is open, determined by the controller, can also affect the amount of lubricant supplied. In certain installations, metered valves (e.g., injectors and / or manifold valves) can be more expensive to implement than non-metered valves, so implementing zones of non-metered valves may be less costly. The flexibility of the System 2300 allows for different types of zones to meet the varying requirements of each installation.

[0132] Fig. Figure 37A is a block diagram of an embodiment of a CAN bus lubrication system 2301 of the invention for supplying zones of distributor valves and zones of injectors with lubricant (see also Fig. 17, which shows a similar zone representation). It is intended that systems 2300 and 2301 can be combined into one system comprising one or more zones of injectors, distributor valves, and / or actuator-controlled valves. System 2301 includes a pump unit 300. The system also includes a valve 2304M, which is opened and closed by a solenoid 2316M to supply lubricant to a zone of injectors 2317 that lubricate bearings 2306M. One of the relays 2318M of the CAN module 2320M is selectively closed to actuate the solenoid 2316M and open the valve 2304M to supply lubricant to injectors 2317 via a lubricant supply line 2302. A pressure sensor 2347 measures the pressure of the lubricant in the line between the valve 2304M and the injectors 2317 and provides a pressure signal to the CAN module 2320M, which sends a corresponding signal to the control unit 2308 via the CAN bus 2310.

[0133] System 2301 also includes a valve 2304N, which is opened and closed by a solenoid 2316N to supply lubricant to a zone of distribution valves 2340 that lubricate bearings 2342. One of the relays 2318M of the CAN module 2320M is selectively closed to actuate the solenoid 2316N and open the valve 2304N to supply lubricant via the lubricant supply line 2302 to the distribution valve 2340B, which supplies lubricant to the distribution valves 2340A and 2340C that lubricate the bearings 2342. A pressure sensor 2346 measures the pressure of the lubricant in the line between the distributor valve 2340C and the bearing 2342E and provides a pressure signal to the CAN module 2320Q, which sends a corresponding signal to the controller 2308 via the CAN bus 2310.A pressure sensor 2348 measures the lubricant pressure in the line between valve 2340A and bearing 2342C and provides a pressure signal to CAN module 2320M, which sends a corresponding signal to controller 2308 via CAN bus 2310. A proximity switch (PX) 2341, assigned to distributor valve 2340C, detects activation of valve 2340C and provides an activation signal to CAN module 2320Q, which sends a corresponding signal to controller 2308 via CAN bus 2310, confirming the activation of valve 2340C.

[0134] Experts will understand that a system according to the invention can be configured with a CAN bus and CAN modules in several different forms with several different types of zones. For example, the system can include sensors and operate as a system with on-demand lubrication in response to the sensors. Such a system may, but need not, include measuring valves in each zone. As another example, the system can be programmed to execute lubrication events according to a schedule, such as every 15 minutes. Such a system may, but need not, include measuring valves in each zone, and may, but need not, include sensors to which the controller responds.

[0135] Each zone can have a zone valve controlled by a zone actuator that responds to a CAN zone module. The zone valve selectively supplies lubricant to the zone. For example, as in Fig. Figure 19 shows valves 1118 zone valves that control the lubricant flow to zones Z1, Z2, and the CAN modules 1121, 1123 are CAN zone modules for controlling zone actuators in association with respective zone valves 1118 for opening and closing the valves 1118.

[0136] The zones may have one or more sensors, such as line pressure sensors 2346, 2347, 2348 for measuring the pressure of the lubricant in one or more supply lines and / or one or more proximity switches 2354 for measuring an adjustment / reset state of one or more distribution valves 2340B.

[0137] The following are examples of various sensors that can be part of the System 2300. The sensors send status signals to the controller to elicit an appropriate response.

[0138] A pressure sensor can be used to monitor the lubricant pressure of the lubricant supply system. In this example, the status signal is a pressure signal, and the controller responds to the pressure signal and triggers an alarm when the pressure signal indicates that the lubricant pressure is less than a minimum pressure setting (see, for example, Figures 1574 and 1578 of the Relief Gauge Test). Fig. 23, which triggers an alarm.)

[0139] A pressure sensor can be used to monitor the lubricant pressure at the cylinder outlet of pump unit 300. In this example, the status signal is a pressure signal, and the controller responds to the pressure signal and triggers an alarm when the pressure signal indicates that the lubricant pressure at the pump is greater than a maximum pressure setting (see, for example, maximum pump pressure). Fig. 24).

[0140] A motion sensor can be used to monitor the movement of the piston in pump unit 300. In this example, the status signal is a motion signal, and the controller responds to this signal and triggers an alarm if the signal indicates that the piston movement is less than a minimum (see, for example, full stroke test). Fig. 25) is (no alarm in Fig. 25).

[0141] A level sensor can be used to monitor the lubricant level in the reservoir of pump unit 300. In this example, the status signal is a level signal, and the controller responds to the level signal and triggers an alarm when the level signal indicates that the lubricant level is lower than a minimum level (see, for example, reservoir level test). Fig. 26).

[0142] A pressure sensor can be used to monitor lubricant pressure in a lubricant line and / or at a lubrication point in the lubricant supply system. As noted, the pressure sensor can be an internal (pump) pressure sensor or a line-end pressure sensor. In this example, the status signal is a pressure signal, and the controller responds to the pressure signal and triggers an alarm when the pressure signal indicates that the lubricant pressure is too low after a certain period of pump motor operation (see, for example, the cycle timeout test (i.e., resetting the injectors)). Fig. 27) is smaller than a minimum pressure setting.

[0143] In one embodiment ( Fig. 37A) The controller 2308 selectively controls the stepper motor 394, and a current sensor 2360 monitors the current applied to the stepper motor 394. In this example, the status signal is a current signal, and the controller responds to the current signal and triggers an alarm when the current signal indicates that the current applied to the stepper motor is greater than a maximum current setting. Alternatively or additionally, as noted herein, the stepper motor current is monitored to selectively overdrive the stepper motor. Alternatively or additionally, as noted herein, the stepper motor current is monitored as an indication of the internal (pump) pressure.

[0144] In some embodiments, an agitator 320 in the container is driven by an agitator motor 326 to mix the lubricant and keep it fluid by reducing its viscosity. In this embodiment, the controller 2308 selectively controls the agitator motor, and a current sensor 2358 monitors the current applied to the agitator motor 326. In this example, the status signal is a current signal, and the controller responds to the current signal and triggers an alarm when the current signal indicates that the current applied to the agitator motor 326 is greater than a maximum current setting (see, for example, lubricant container stiffness test). Fig. 28).

[0145] As noted herein, the controller may be a processor, in which case it would comprise a tangible, computer-readable, non-volatile storage medium containing instructions executable by the processor for controlling the operation of the processor. In this embodiment, the processor is programmed by an operator to execute one or more of the following sets of instructions: (i) Instructions for determining whether a lubricant injector connected to the system is relieving and for triggering an alarm if the relieving gauge test indicates that the injector is not relieving; (ii) Instructions for determining a lubricant pressure at the cylinder outlet of the pump unit and for triggering an alarm when the determined pressure is greater than a maximum pressure; (iii) Instructions for determining a piston movement and for triggering an alarm if the determined piston movement is less than a minimum movement; (iv) Instructions for determining the lubricant level of the reservoir and for triggering an alarm if the determined lubricant level is below a minimum level; and / or (v) Instructions for determining a lubricant pressure and for triggering an alarm if the determined pressure is less than a maximum pressure after a certain period of motor pump operation.

[0146] The 2310 control local area network (CAN) bus system and the features described above were described in the context of lubrication systems incorporating the previously described 300 pump unit. However, it is understood that the same self-diagnostic features can be used in lubrication systems with other pump units, such as the 2500 and 2900 pump units described below, and other lubricant pump units incorporating a stepper motor or an alternative linear position drive mechanism (e.g., the mechanism from [reference missing]). Fig. 20 or Fig. 21).

[0147] Similarly, the self-diagnostic features were described in connection with lubrication systems incorporating the previously described pump unit 300. However, it is understood that the same self-diagnostic features can be used in lubrication systems with other pump units, such as the pump units 2500 and 2900 described below, and other lubricant pump units incorporating a stepper motor or an alternative linear position drive mechanism (e.g., the mechanism from [reference missing]). Fig. 20 or Fig. 21).

[0148] Fig. Figures 38-54 show a further embodiment of a pump unit of this invention, which is generally designated 2500. The pump unit is similar to the pump unit 300 described above. It comprises a container 2504 for holding a supply of lubricant (e.g., grease) and a pump housing 2506 below the container for housing various pump components of the unit, including a pump cylinder 2508 and a piston 2512, which is movable back and forth in the cylinder (see Figure 38-54). Fig. 41 and Fig. 42).

[0149] Referring to Fig. 38 and Fig. In the container 2504, a tank 2518 is formed with a side wall 2520, a removable top 2526, and no bottom wall. The lower end of the side wall 2520 rests on the pump housing 2506. A number of tie rods 2530 connect the cover 2526 to the pump housing 2506 and hold the tank in position within the housing. The cover 2526 can be removed by unscrewing nuts 2532 on the tie rods 2530. The tank 2518 has an interior 2536 for receiving a supply of lubricant (e.g., grease). A spring-loaded plunger 2538, mounted on a vertical central shaft 1939 within the tank 2518, bears against the grease and wipes along the inner surface of the tank as the grease level decreases during operation of the pump unit 2500.

[0150] Referring to Fig. 39 and Fig. The pump housing 2506 comprises a top wall 2540, a side wall 2542 forming a rim extending down from the top wall, and a bottom wall 2546. A sleeve 2548 extends upwards from the top wall 2540 and is dimensioned to accommodate the lower end of the reservoir tank 2518. A seal 2550 on the sleeve 2548 forms a seal against the side wall 2520 of the tank to prevent leakage. A refill port 2554 is provided on the housing 2506 for refilling the reservoir tank 2518 with lubricant. A refill line 2556 connects the refill port 2554 to an outlet opening 2560 in the top wall 2540 of the housing. The outlet opening 2560 is connected to the interior 2536 of the tank 2518 so that lubricant can flow into the tank to refill it.In a dual-line system, the refill port 2554 is connected to the return line to provide access to the tank 2518 and to supply the tank with the lubricant provided by the return line.

[0151] The pump cylinder 2508 is mounted in the pump housing 2506 directly below the upper wall 2540 of the housing. As shown in Fig. 41 and Fig. As shown in Figure 42, the pump cylinder comprises a cylinder body 2562 and a valve housing 2564, which engages in threaded engagement with the cylinder body. The cylinder body 2562 is shown as a two-part assembly, but can comprise any number of parts. The cylinder body 2562 and the valve housing 2564 have coaxial longitudinal bores, designated 2566A and 2566B respectively, forming a longitudinal cylinder bore 2566. The piston moves back and forth in bore 2566A, which in this embodiment has a diameter D1. To accommodate various check valve components, bore 2566B in the valve housing 2564 has a variety of diameters, as will be described later.

[0152] The cylinder body has an inlet comprising an inlet channel 2570 extending from a surface 2572 of the body to the cylinder bore 2566. The surface 2574 engages with the seal (via the seal 2576 in Fig. 43) with an opposing surface 2578 of the upper wall 2548 of the pump housing 2506. The upper wall 2548 of the pump housing has an opening 2582 that is aligned with the inlet channel 2570 to form a defined, tunnel-like flow path 2586 from the interior 2536 of the tank 2518 to the cylinder bore 2566. The flow path 2586 is closed along its entire length from the interior of the tank 2536 to the cylinder bore 2566. Desirably, the flow path 2586 is a generally straight path that generally extends vertically from an upper end of the flow path to a lower end of the flow path. Also desirable is that the overall length of the defined flow path 2586 is relatively short (e.g., less than 10.16 cm; preferably less than 7.62 cm and particularly less than 5.08 cm).

[0153] Referring to Fig. The opening 2582 in the upper wall 2548 of the pump housing 2506 is generally conical and defines an outlet of a tank 2518. The opening 2582 has a large-diameter upper end to facilitate the flow of lubricant from the tank 2518 into the opening, and a smaller-diameter lower end. The tapered opening 2582 funnels the lubricant into the inlet channel 2570 of the cylinder 2508. The opening 2582 has an upper end diameter D2, a lower end diameter D3, and an axial length L1.

[0154] The cylinder intake port 2570 has an upper section 2570A, which is essentially cylindrical (with a slight taper for easier manufacturing) and coaxial with the opening 2582 in the upper wall 2548 of the housing 2506. The upper section 2570A has a diameter D4 and an axial length L2. The intake port 2570 also has a lower section 2570B, which is elongated (e.g., oval) when viewed in horizontal cross-section (see Fig. 44 and Fig. 45). The elongated section 2570B has a major dimension D5, generally transverse to the longitudinal centerline 2588 of the cylinder bore, which is approximately equal to the full diameter D1 of the cylinder bore 2566 at the junction of the intake port 2570 and the cylinder bore; a shorter subdimension D6, generally parallel to the longitudinal centerline of the cylinder bore and smaller than the full diameter of the cylinder bore 2566A; and a length L3. The elongated configuration maximizes the flow area into the cylinder bore 2566 and reduces the effective length of the piston working stroke, i.e., the segment of the working stroke after the piston 2512 has moved past the cylinder intake port 2570 and closed the junction between the cylinder bore 2566 and the intake port. In this way, the pump unit 2500 is more compact and yet still pumps a relatively large volume of lubricant (e.g.,at least 1.5 cubic centimeters) per piston pump stroke.

[0155] The following are example dimensions. They are for illustrative purposes only. D1−0.435 inch D2−1.033 inch D3−0.500 inch D4−0.440 inch D5−0.435 inch D6−0.187 inch L1−0.840 inches L2−0.840 inches L3−1.125 inch L4−0.425 inch (slot interior)

[0156] The defined flow path 2586 can have other configurations, wherein the path is formed by a tunnel-like channel with an open upper end for the direct entry of the lubricant from the interior 2536 of the tank 2518 into the channel and an open lower end for the direct exit of the lubricant from the channel into the cylinder bore 2566. The defined flow path can be formed by any number of separate channel-forming elements (e.g., the upper wall 2548 of the pump housing 2506 and the cylinder body 2562) having matching openings that, when combined, form a closed tunnel-like channel, which is closed except for one end for the direct entry of the lubricant from the interior of the tank into the channel and an opposite end for the direct exit of the lubricant from the channel into the cylinder bore 2566.

[0157] Referring to Fig. Figures 45-47 describe an agitator, generally designated 2600, which serves to stir the lubricant in the tank 2518. The agitator 2600 comprises a rotary hub 2602, which is rotatable about a vertical axis 2604 by a first drive mechanism 2606 in the pump housing 2506. An arm 2610 extends radially outward from the hub 2602 adjacent to the bottom of the tank 2518, generally horizontally. An upright stirring element 2614 at the outer end of the arm 2610 extends upward along the cylindrical side wall 2520 of the tank 2518. Rotation of the agitator 2600 fluidizes the lubricant in the tank and destroys any air bubbles that may be present in the lubricant, thus reducing the risk of the pump unit 2500 losing its suction power.

[0158] Referring to Fig. The stirrer drive mechanism 2606 comprises an electric motor 2616 and a gearbox 2618, which connects the output shaft 2620 of the motor to the hub 2602 of the stirrer 2600. The rotation of the output shaft 2620 acts via the gearbox 2618 to rotate the stirrer 2600 about the vertical axis 2604 at a suitable speed (e.g., 40–60 rpm). The stirrer hub 2602 is attached to an output shaft 2624 of the gearbox by means of a suitable device (e.g., an adjusting screw) so that the hub rotates together with the output shaft. A spacer 2626 at the upper end of the agitator hub 2602 supports the lower end of the plunger shaft 2539. The spacer 2626 is attached to the agitator hub by means of a suitable device (e.g. an adjusting screw) so that it rotates together with the agitator hub.The lower end of the tappet shaft 2539 is received in an opening 2628 in the upper end of the spacer 2626 and remains stationary while the spacer rotates with the hub 2602.

[0159] The agitator 2600 has a pressure lubrication mechanism 2630, which is actuated by rotating the agitator to drive lubricant under pressure out of the tank through the tank outlet, i.e., through the opening 2582. As shown in Fig. 46 and Fig. As shown in Figure 47, the pressure lubrication mechanism 2630 comprises a pressure lubrication element 2632 on the arm 2610 of the agitator. The pressure lubrication element 2632 extends along the arm and has a downwardly inclined lower surface 2636 lying in a plane oriented at an angle 2648 relative to the top wall 2540, thus essentially forming the bottom of the vessel. The pressure lubrication element 2632 terminates at a lower end 2638 located a relatively small distance (e.g., 0.16 in) from the top of the wall 2540. A rotation of the stirrer 2600 causes the angled pressure lubricating element 2632 to move through the lubricant and generate a pressure force that pushes the lubricant downwards through the opening 2582 in the upper wall 2540 of the pump housing 2506 and along the defined flow path 2570 to the cylinder bore 2566.

[0160] The downward compressive force exerted on the lubricant by the pressure lubrication mechanism 2630 is complemented by a tensile force exerted on the lubricant by the pump piston 2512 during its return stroke. In this respect, it is understood that the return stroke of the piston 2512 generates a reduced pressure in the cylinder bore 2566, which draws the lubricant down the flow path 2570 towards the cylinder bore. Ideally, the control unit of the pump 2500 is programmed to operate the agitator 2600 and the piston 2512 simultaneously, so that the compressive and tensile forces act concurrently (in concert) to move the lubricant along the defined flow path 2570 into the cylinder bore 2566. Combined, these forces can move the lubricant more powerfully from the reservoir to the cylinder bore.Furthermore, these forces are maximized because the flow path 2570 from the interior of the tank 2536 to the cylinder bore 2566 is sealed against atmospheric pressure along its entire length. In this way, the pump unit 2500 can also pump more viscous lubricants at lower temperatures than conventional pump units.

[0161] The advantage of the push-pull arrangement described above is evident in the curve. Fig. Figure 48 illustrates the results of tests conducted using a prior art Lincoln Industrial pump (Model 653) and a pump unit configured as described above in the 2500 pump unit. The lubricant used in the test was a lithium-moly grease of NLGI 2 grade with a yield strength of 800 psi, as measured by the unload gauge test described above and in U.S. Patent 7,980,118, incorporated herein by this document. (The National Lubrication Grease Institute (NLGI) defines standard designations for grease consistency.) As shown by the curve, the push / pull forces exerted by the pump unit of our new arrangement can pump the grease at a significantly lower temperature (at least 15 degrees less) than the prior art arrangement.

[0162] Referring to Fig. 42 A first ball check valve 2670 is mounted in the valve housing 2564 to move in the bore 2566B between a closed position, in which it engages with a first valve seat 2672 on the housing to block the flow through the cylinder bore 2566 during a return stroke of the piston 2512, and an open position, in which it allows the flow through the bore during a pump stroke of the piston. A first compression coil spring 2676, which reacts at one end against the ball valve 2670, drives the ball valve into its closed position. The opposite end of the spring 2676 reacts against a second ball check valve 2678 downstream of the first ball valve 2670.The second ball check valve 2678 is mounted in the valve housing 2564 to move within the bore 2566B between a closed position, in which it engages with a second valve seat 2680 on the housing to block flow through the cylinder bore 2566 during a return stroke of the piston 2512, and an open position, in which it allows flow through the bore during a pump stroke of the piston. A second compression coil spring 2682, which reacts at one end against the second ball valve 2678, drives the ball valve into its closed position. The opposite end of the spring 2682 reacts against a plug 2684, which is screwed into the downstream end of the bore 2566B.The use of two check valves 2670, 2678 instead of a single check valve (as in the first embodiment described above) reduces the risk of lubricant flowing back into the inlet part 2508A of the cylinder during a piston return stroke.

[0163] Referring to Fig. 49 and Fig. The pump cylinder 2508 has an outlet which includes an outlet port 2700 in the cylinder body 2562. The outlet port 2700 communicates with the cylinder bore 2566 via an annular gap 2702, which is arranged between the valve housing 2564 and the cylinder body 2562, and a connecting channel 2704, which extends between the annular gap and the bore 2566B in the valve housing at a position downstream of the second ball check valve seat 2680. A lubricant outlet fitting 2708 is screwed into the outlet port 2702. In the illustrated embodiment, the outlet nozzle 2708 is a T-nozzle so that the lubricant flows to a first supply line 2714, which is attached to the pump housing 2506 at one position, and to a second supply line 2716, which is attached to the pump housing at a second position, which is arranged at a distance around the housing in relation to the first position.The outlet of each supply line 2714, 2716 is fitted with a self-sealing quick connector 2720 to facilitate connection of the supply line to a lubricant supply line that supplies lubricant to a distribution system of one type or another. Generally, only one of the two supply lines is used for a given distribution system, with the supply line to be used being the configuration best suited to the local conditions. However, in some installations, both supply lines may be used.

[0164] Referring again to Fig. 49 and Fig. The cylinder body 2562A also has a sensor opening 2724, which is connected to the bore 2566B by means of the annular gap 2702 and the connecting channel 2704. A pressure sensor 2726, which is screwed into the sensor opening, measures the pressure at the outlet end of the cylinder bore 2566.

[0165] As in Fig. As shown in Figure 42, a relief channel 2730 in the cylinder body 2562 provides a fluid connection between a first position in the longitudinal cylinder bore 2566A upstream of the first check valve seat 2672 and a second position in the longitudinal cylinder bore 2566B downstream of the second check valve seat 2680. The downstream end of the relief channel 2730 communicates with the second position via the outlet port 2700, the annular gap 2702, and the connecting channel 2704. The purpose of the relief channel 2730 is the same as that of the relief channel 376 described in the first embodiment. Other configurations of the relief channel are also possible.

[0166] Referring to Fig. 51-54 The piston 2512 of the pump unit 2500 comprises a hollow cylindrical piston body 2720 with a front (right) end and a rear (left) end. The body 2720 has an internal thread 2722 that generally extends from the rear of the body to the front end, but preferably terminates relatively far from the front end. The front end of the piston body 2722 is closed by a piston head 2726 with a circumferential seal 2728, which provides a seal on the inner surface of the body.

[0167] The piston 2512 can be moved back and forth in the cylinder bore 2566 by a second drive mechanism, generally designated 2740. In the embodiment shown Fig. Figures 51-54 describe the drive mechanism 2740 as a linear position drive mechanism comprising a stepper motor 2742 with an output shaft 2744 connected to a coaxial leadscrew 2746 rotatably mounted in a sliding bearing 2750 in an end wall 2752 of a plunger housing 2756. The leadscrew 2746 includes a leadscrew body 2760 with a blind bore 2762 that receives the output shaft 2744 of the stepper motor 2742, and a threaded shaft 2766 extending forward from the body. The shaft 2766 has an external thread 2768 configured to match the internal thread 2722 of the plunger body 2720. The stepper motor output shaft 2744 is keyed to the body 2760 of the leadscrew at 2770, so that the shaft and the leadscrew rotate together. Ideally, the matching threads on the piston and the leadscrew are designed for efficient power transmission.For example, threads 2722, 2768 can be full ACME threads capable of carrying a substantial load to pump lubricant at high pressure.

[0168] The compressive loads exerted on the piston 2512 and the leadscrew 2746 are supported by the first and second thrust bearings 2774, 2776 on opposite sides of the end wall 2752 of the tappet housing 2756. The first thrust bearing 2774 carries axial loads in the reverse direction (i.e., in the direction of travel) during a pump stroke of the piston 2512, as it moves forward in the cylinder bore 2566A. Fig. 51 to the left). The thrust bearing 2774 comprises a needle bearing 2780 and two bearing raceways 2782, which are held rotationally secure between the tappet housing end wall 2752 and a radial circumferential flange 2784 on the leadscrew body 2760. The second thrust bearing 2776 carries axial loads in the forward direction (i.e., in) during a pump stroke of the piston 2512, when it moves backward in the cylinder bore 2566A. Fig. 51 to the right). The thrust bearing 2776 comprises a needle bearing 2786 and two bearing raceways 2788, which are held rotationally secure between the tappet housing end wall 2752 and a retaining ring 2790 on the leadscrew. A seal 2792 in a counter bore in the tappet end wall 2752 immediately in front of the second thrust bearing 2776 seals against the leadscrew body 2760 to prevent leakage.

[0169] A tappet 2800 is secured to the piston 2512 for a linear (non-rotating) back-and-forth movement of the tappet and piston in a cavity 2802 in the tappet housing 2756. The cavity 2802 extends forward from the end wall 2752 of the housing 2756, which is generally adjacent to the rear end of the housing, to the front end of the tappet housing. In this embodiment, the longitudinal centerline of the cavity 2802 is generally coaxial with the longitudinal centerline of the piston 2512 and the leadscrew 2746. The front end of the tappet housing 2750 seals against the rear end of the cylinder body 2562, such that the longitudinal centerline of the cavity 2802 is generally coaxial with the longitudinal centerline of the cylinder bore 2566, and such that the piston 2512 extends from the tappet cavity into the cylinder bore to move back and forth in the cylinder bore 2566A.

[0170] As in Fig. As shown in Figure 53, the tappet 2800 comprises a circular tappet body 2806 with a central bore 2808, having a large-diameter rear section 2808A that accommodates the circumferential flange 2784 on the leadscrew body 2760 and part of the first thrust bearing 2774, and a smaller-diameter front section 2808B that accommodates the rear end section of the piston body 2720. The smaller-diameter section 2808B of the tappet bore 2808 and the rear end section of the piston body 2720 are not circular (e.g., rectangular) to prevent relative rotational movement between the piston and the tappet. A relative axial movement between the two parts is prevented by an inwardly projecting circumferential flange 2812 on the plunger body 2806, which is held in a rotationally secure manner between an outwardly projecting circumferential flange 2814 on the piston body and a retaining clamp 2820 on the piston body.Other designs are possible to prevent relative rotation and linear movement between the piston 2512 and the tappet 2800.

[0171] As in Fig. As shown in Figure 54, the tappet body 2806 has notches 2824 for receiving stationary linear guides, which are defined by rails 2826 on the inside of the tappet housing 2756. The rails 2826 extend in one direction generally parallel to the longitudinal cylinder bore 2566 and secure the tappet 2800 (and the piston 2512) against rotation while the leadscrew 2746 is rotated by the stepper motor 2742. In this way, rotation of the motor output shaft 2744 and the leadscrew 2746 in one direction causes the piston 2512 to move linearly in the cylinder bore 2566A by means of a pump stroke, and rotation of the output shaft 2744 and the leadscrew 2746 in the opposite direction causes the piston to move linearly in the cylinder bore by means of a return stroke. The length of the pump stroke and the return stroke are controlled by the operation of the stepper motor 2742, which in turn is controlled by the controller.

[0172] Desirably, the cavity 2802 serves as a container for receiving a lubricant (e.g., oil) suitable for lubricating the threads 2722 and 2768 on the leadscrew 2746 and on the piston 2512. Furthermore, an oil supply mechanism is provided to direct oil from the container to the threads. In the illustrated embodiment, the oil supply mechanism comprises a section of the leadscrew 2746 that includes the flange 2784 on the leadscrew body 2760. The flange 2784 is dimensioned to be immersed in the oil in the container 2802. As the spindle 2746 rotates, the flange 2784 carries oil from the reservoir upwards to a position above the leadscrew, where the oil flows down a front surface of the flange 2784 through a gap 2830 between the flange and the rear end of the piston body 2720 to be supplied to the thread on the leadscrew's threaded shaft.Notches 2834 are provided on the circumferential edge of the flange 2784 to increase the amount of fluid carried by the flange. In this embodiment, two diametrically opposed, generally U-shaped notches 2834 are provided, but the number and shape of the notches can vary. Other oil supply mechanisms can also be used.

[0173] An oil return mechanism is provided to return excess oil supplied to the corresponding threads 2722, 2766 on the piston body 2720 and on the leadscrew shaft 2766 to the reservoir 2802. In the illustrated embodiment, the oil return mechanism comprises an axial groove 2840 extending along the outer surface of the threaded shaft 2766 of the leadscrew. Any excess oil on the shaft 2766 moves along the groove 2840 to be guided back to the reservoir 2802 through the gap 2830 between the front surface of the leadscrew flange 2784 (on the front of the leadscrew body 2760) and the rear end of the piston body 2720. A channel 2844, extending longitudinally through the tappet body 2806, allows the lubricant in the reservoir 2802 to flow past the tappet 2800 as the tappet and piston move back and forth in the cavity.

[0174] Referring to Fig. 44 The tappet housing 2756 has an inlet port 2850 to allow oil to flow into the cavity from a suitable source. The inlet port can also be used to drain oil from the cavity.

[0175] A calibration mechanism that is in Fig. The mechanism 2860, generally designated as 2860, is provided for a calibration process of the stepper motor 2742 relative to the position of the piston 2512 in the cylinder bore 2566. In the illustrated embodiment, this mechanism 2860 comprises a magnet 2862 on the plunger 2800, which can move with the piston 2512, and at least one, and preferably two, magnetic field sensors 2864, 2866, which are mounted at intervals on the plunger housing 2756 with respect to the direction of the piston movement. The control unit of the pump unit 2500 receives signals from the calibration mechanism 2860 and calibrates the operation of the linear position drive mechanism 2740 relative to the position of the piston 2512 in the cylinder 2508.

[0176] Other linear position drive mechanisms can also be used to move the piston 2512 back and forth in the cylinder bore 2566. Examples of alternative drive mechanisms are given in Fig. 20 and Fig. 21 shown and described above.

[0177] The operation of pump unit 2500 is essentially the same as that of pump unit 300 described above. The control unit of pump unit 2500 features a programmable microprocessor that processes information. The control unit calibrates and controls the operation of the linear position drive mechanism 2740 and responds to signals received from the pressure sensor 2726 and the calibration mechanism 2860 (e.g., magnetic field sensors 2864, 2866). The control unit also controls the operation of the stirrer motor 2606 and the stepper motor 2742. Ideally, the control unit initiates the operation of the stirrer motor 2606 before the stepper motor 2742 is operated to move the piston 2512 back and forth.This sequence allows the agitator 2600 to fluidize the lubricant and prepare the pump cylinder 2508 with lubricant before the actual pumping of the lubricant begins. This can be particularly advantageous when the lubricant is in a viscous state, such as in cold environments. After a suitable delay of a predetermined duration (e.g., eight to twelve seconds), the stepper motor 2742 is activated to move the piston 2512 through a series of one or more pumping and return strokes to pump the desired quantity of lubricant through the supply line 2714, 2716, which is connected to the distribution lubricant supply line.

[0178] When the pump unit 2500 is operated in a non-relieving mode, the piston 2512 moves forward in the cylinder bore 2566 during a pumping stroke to pump lubricant from the cylinder bore 2566, and backward during a non-relieving return stroke, in which the piston stops just before the position where the relief channel 2730 communicates with the cylinder bore 2566A. That is, the limit of the return stroke is downstream of the position where the relief channel 2730 communicates with the cylinder bore 2566A. As a result, the relief channel 2730 does not communicate with the interior 2536 of the tank 2518, and no relief of the distribution system occurs during a return stroke of the piston. As explained previously, such relief is unnecessary in a progressive (divider) valve distribution application.

[0179] When the pump unit 2500 is used with an injector distribution system requiring relief, the pump unit's control system is programmed to pump the desired quantity of lubricant at desired time intervals through a lubricant supply line to multiple injectors. The injectors are operated in such a way that they provide metered quantities of lubricant to the respective lubrication points (e.g., bearings). In this mode, the pump unit 2500 operates as described above, except that the piston 2512 moves forward in the cylinder bore 2566 by a pumping stroke to pump lubricant from the cylinder bore 2566 and moves backward by a relief stroke, passing the position where the relief channel 2730 communicates with the cylinder bore 2566A.This means that the limit of the return stroke is upstream of the position where the relief channel 2730 connects to the cylinder bore 2566A. In this way, the relief channel 2730 connects to the interior of the tank (via the cylinder bore 2566A and the defined flow path 2586), and lubricant is drained to the tank so that the injectors can reset for the next lubrication event.

[0180] Thus, the piston 2512 of the pump unit 2500 can be moved by both relieving and non-relieving return strokes, depending on whether the distribution system supplied with lubricant by the pump unit requires relieving between lubrication events. In the embodiment described above, a relieving return stroke of the piston 2512 is slightly longer than a non-relieving return stroke of the piston.

[0181] The pump unit 2500 is capable of pumping viscous lubricants at relatively low temperatures. This is due, at least in part, to the strong pressure / tension force exerted on the lubricant to force it from the container directly into the cylinder bore 2566. As explained above, the rotation of the agitator 2600 causes the pressure lubrication mechanism 2630 to exert a strong downward force on the lubricant inside the tank 2518, 2536, forcing it along the flow path 2586 toward the cylinder bore 2566A. Furthermore, a return stroke of the piston generates a force that pulls this same lubricant along the same defined flow path 2586. The combination of these pressure and tension forces is effective in moving viscous lubricant into the cylinder bore at lower temperatures.

[0182] The use of an agitator and the pressure lubrication mechanism of the type described above is not limited to the 300 and 2500 pump units. The agitator and pressure lubrication mechanism can be used in any type of pump unit, where lubricant is conveyed along a defined flow path from a reservoir to an inlet of a cylinder in which a piston moves back and forth to deliver lubricant to a lubrication distribution system. The piston can be moved back and forth by any type of linear or nonlinear drive mechanism.

[0183] Furthermore, the characteristics of moving a piston in a cylinder by forward pump strokes and by backward relieving and non-relieving return strokes of varying lengths can be used in lubricant pump units other than the 300 and 2500 pump units. The piston can be moved back and forth by any type of linear or nonlinear drive mechanism using such strokes to pump lubricant to relieved (e.g., injector) lubricant distribution systems and non-relieved (e.g., distributor valve) lubricant distribution systems.

[0184] In other embodiments, the tank 2518 of the container 2504 can have a bottom wall that overlaps the top wall 2540 of the pump housing 2506. In such embodiments, the tank bottom wall has an outlet opening to allow lubricant to escape from the tank. Desirably, this outlet opening forms part of a defined flow path from the interior of the tank to the cylinder bore. One such embodiment is described below.

[0185] Fig. 55A, Fig. 55B, Fig. 55C and Fig. Figure 55D shows a device for supplying lubricant, generally designated 2900, which is very similar to the pump unit 2500 shown above. Fig. 38-54. The device 2900 comprises a pump assembly with a pump housing 2902 and a lubricant pump, generally designated 2906, in the housing for pumping lubricant to one or more lubrication points. The pump 2906 comprises similar components to the pump unit 2500 described above, including a piston 2908, which is actuated by a linear drive mechanism 2912 (e.g., a stepper motor 2914) and plunger 2916 of the above. Fig. The pump 2906 (of the type described in sections 38-54) is movable in a cylinder bore 2910, has an inlet 2920 connected to the cylinder bore to receive lubricant, and an outlet 2924 connected to the cylinder bore to discharge lubricant at a higher pressure than that of the lubricant at the inlet. In general, the pump 2906 operates in the same manner as described above for the pump unit 2500.

[0186] The device also includes a container 2930, which comprises a tank 2932 measured to hold a volume of lubricant. The tank has a side wall 2936 and a removable top 2938. The side wall 2936 of the tank sits on the pump housing 2902. The container also includes an agitator, generally designated 2940, for stirring the lubricant in the tank 2932, and a spring-loaded plunger 2942 in the tank, which bears against the lubricant (e.g., grease) and wipes along the inner surface of the side wall 2936 of the tank as the level of the grease decreases during operation of the pump unit 2900. The agitator 2940 and the plunger 2942 can be similar in construction and operation to the agitator 2600 and the plunger 2538 described above for the pump unit 2500.

[0187] The pump housing 2902 has a top wall 2950 and a side wall 2952. The top wall 2950 has an opening 2954, which forms an outlet of the tank. The opening 2954 is arranged above the inlet 2920 of the pump 2906 to allow lubricant to flow from inside the tank 2932 along a defined flow path as described above in relation to the embodiment. Fig. to direct the type described in 38-54 to the cylinder bore 2910.

[0188] A temperature sensor 2956 is attached to a projection formed on a lower surface 2958 of the upper wall 2950. A heater 2960 (e.g., a 100 W cartridge-type resistance heater) is also mounted in the pump housing. In the illustrated embodiment, the heater 2960 is attached to the lower surface 2958 of the upper wall 2950. By way of example, but not limited to, the heater 2960 comprises a 100 W cartridge-type resistance heater to raise the temperature of the lubricant in the tank 2932 to -12.22 °C to -9.44 °C. Although the heater 2960 can be attached to the lower surface 2958 of the upper wall 2950 by other means, in one embodiment the heater is attached to the upper wall by a conventional pipe clamp 2962. The sensor 2956 can also be attached to the upper wall 2950 using a standard pipe clamp 2964.

[0189] The temperature sensor 2956 has conductors 2970 that are connected to a controller or processor, as previously described. The heater 2960 can be activated before startup or as soon as a signal is received from the temperature sensor 2956 indicating a temperature below a predetermined minimum (e.g., -6.66 °C). Desirably, the pump housing 2902 is made of a thermally conductive material, and the bottom of the reservoir tank (which in this embodiment is bounded by the top wall 2950 of the pump housing 2902) is made of a thermally conductive material such as aluminum, so that thermal energy provided by the heater 2960 heats the lubricant in the reservoir to maintain the lubricant at a suitable stiffness for pumping. Since other features of the pump unit 2900 are similar to those already described, they are not described in detail here.Since control systems for controlling heaters are generally known, they do not need to be described in detail here.

[0190] Alternatively, the tank 2932 can have a bottom wall (2978, Fig. 55E) which is separated from and overlaps the upper wall 2950 of the pump housing 2902, thereby creating an interface between an upper surface 2980 of the upper wall 2950 of the housing and a lower surface 2982 of the bottom wall 2982 of the tank. To promote heat conduction at this interface, the opposing surfaces are preferably contoured, measured, and shaped for surface contact. In one embodiment, the opposing surfaces are flat to ensure surface contact. For example, the area of ​​the lower surface 2982 of the bottom wall 2978 of the tank 2930, which is in contact with the upper surface 2980 of the upper wall 2950 of the pump housing 2902, can constitute at least 70%, or at least 75%, or at least 80% of the total area of ​​the lower surface of the bottom wall of the tank.

[0191] As above in relation to Fig. 28 noted, the processor's self-diagnosis may be in response to the fact that the reservoir lubricant is too stiff, as indicated by the reservoir lubricant stiffness test. Fig. The processor can control the heater 2910 based on the temperature of the lubricant. Alternatively or additionally, the processor can be connected to a temperature sensor that provides a reading of the ambient temperature of the lubrication system, and the heater can be controlled by the processor in response to the measured ambient temperature. Depending on the type of lubricant, the heater can, for example, be controlled when the measured ambient temperature is below a user setting (e.g., 4.44 °C). Alternatively or additionally, the processor can be connected to a temperature sensor that provides a reading of the lubricant temperature, and the heater can be controlled by the processor in response to the measured lubricant temperature. In this embodiment, the sensor can be located in the lubricant to measure the temperature of the lubricant itself, or the sensor can be located adjacent to a component of the pump unit (e.g., the pump unit).the pump housing on which the reservoir sits) to measure a temperature that indicates the lubricant temperature.

[0192] The heater feature described above is described in connection with a specific lubricant pump unit 2900. However, it is understood that this feature can also be used in other lubricant pump units with a lubricant reservoir made of thermally conductive material, regardless of the pump drive mechanism, and mounted on a pump housing made of thermally conductive material.

[0193] There are several ways to program the main controller 450 to control a motor driver circuit 451 to drive the stepper motor 394, which in turn rotates the leadscrew 410, causing the piston 384 to move back and forth and pump lubricant. In one embodiment, for example, the controller 450 can be programmed to cause the motor driver circuit 451 to rotate the motor shaft 396 clockwise for a predetermined time and then counterclockwise for a predetermined time. In another embodiment, the controller 450 can be programmed to cause the motor driver circuit 451 to rotate the motor shaft 396 clockwise for a predetermined number of revolutions and then counterclockwise for a predetermined number of revolutions.

[0194] In another embodiment, magnetic field sensors 440, 442, such as reed switches or Hall sensors, can be arranged at or near the ends of the cylinder bore 338 or at or near the ends of the pump stroke to measure the position of the piston or the tappet. A magnet 434 can be attached to the piston 384 or the tappet 414 to indicate the piston position and to be measured by the sensors. In this embodiment, the main control 450 moves the piston back and forth in response to the sensors.In particular, the controller 450 can be programmed to cause the motor driver circuit 451 to rotate the motor shaft 396 clockwise until the switches / sensors indicate that the piston position is at or near the end of the cylinder bore 338 (at one end of the pump stroke), and then to rotate the motor shaft 396 counterclockwise until the switches / sensors indicate that the piston position is at or near the other end of the cylinder bore 338 (at the other end of the pump stroke). The switches / sensors can be used for calibration or during stepper motor operation to determine the piston position, or, as noted here, to monitor the piston position during a diagnostic procedure.

[0195] In one embodiment (described below), the stepper motor is controlled by PWM pulses to move the piston forward by means of a power stroke to a position measured by the forward sensor 442. The stepper motor is then reversed and controlled by PWM pulses to operate the piston in a reverse direction by means of a return stroke, either with or without a return stroke. The length of the return stroke is determined by applying a predetermined number of PWM pulses to the stepper motor to move the piston backward from its forward position, as measured by the forward sensor 442.

[0196] In another embodiment, the controller 450 has an integrated motor driver circuit and controls the operation of the stepper motor 394 by controlling the driver circuit to selectively apply PMW pulses to the stepper motor 394 and to control the motor's speed and torque to move the piston back and forth. The controller also responds to one or more pressure sensors that measure the lubricant pressure, such as the pressure sensor 372 for measuring the pressure at the cylinder bore outlet. The pressure sensor provides a pressure signal indicating the measured pressure of the lubricant supplied via the cylinder outlet. The controller 450 responds to the pressure signal to selectively apply the PMW pulses to the stepper motor 394 to vary the stepper motor's speed and torque as a function of the pressure signal by applying PMW pulses with a power within a continuous operating range of the stepper motor.In some embodiments, the pressure sensor can be a sensor for measuring the current of the motor 394, since the motor current indicates the pressure, therefore the pressure signal can be a signal indicating the motor current.

[0197] The speed of the 394 stepper motor can be controlled by the duty cycle of the PWM pulses applied to the motor. The speed of the 394 stepper motor can be controlled by the width (i.e., duration) of these PWM pulses. In this way, the PWM pulses have a voltage (pulse amplitude) and a current (pulse width) that result in a specific power level being applied to the motor. Generally, the stepper motor can be controlled by adjusting the motor voltage, motor current, pulse duty cycle, and / or pulse power.

[0198] Fig. Figure 56 is a diagram that shows an exemplary performance curve 3000 (or motor temperature curve) over time for the stepper motor and also shows an exemplary continuous operating range 3001 of the stepper motor. When the motor operates in this range 3001, internal heat is generated so that the motor temperature is at or below a critical temperature 3003. Often, the continuous operating range 3001 is based on various characteristics of a motor, such as its size and materials. When a motor is operated within the continuous operating range 3001, its temperature stabilizes below the critical temperature 3003, so that the motor can be operated for extended periods without significant adverse effects.However, if a motor is operated above the continuous operating range 3001, its temperature stabilizes above the critical temperature 3003, so that the motor can only be operated for a limited time without significant adverse effects. If, however, a motor is operated above the continuous operating range and its temperature stabilizes above the critical temperature 3003, and if the motor is operated beyond the limited time, significant adverse effects may occur.

[0199] In Fig. Section 56 defines the performance curve 3001 as the approximate difference or limit between operating the motor for a period of time without significant adverse effects and operating the motor for a period of time with significant adverse effects. Operating the motor at a power level and for a period of time that lies within a range 3002 below the dashed line 3004 falls within the continuous operating range 3001, and no significant adverse damage occurs. The dashed line 3004 is generally referred to as the continuous operating range of the motor.

[0200] Operating the motor at a power level and for a duration within range 3006 above the dashed line 3004 and to the left of curve 3000 (above and beyond range 3002 of the continuous operating range 3001) does not cause significant adverse damage, as the duration is relatively short and no excessive heat builds up in the motor. Operating the motor at a power level and for a duration within range 3008 above the dashed line 3004 and to the right of curve 3000 (above and beyond range 3002 of the continuous operating range 3001) causes significant adverse damage, as excessive heat builds up in the motor, causing damage. Generally, applying increased power to the stepper motor leads to a corresponding increase in the motor's temperature. For some stepper motors, 80°C is specified as the maximum motor temperature rating.For such engines, the operation of the engine to the left of curve 3000 would therefore be off. Fig. 56 an operation within the engine dimension, while an operation of the engine to the right of curve 3000 from Fig. 56 would be in operation outside the engine's design parameters.

[0201] Operating the motor at power level W1 for a time interval T1 to T2 within the range 3006 above the dashed line 3004 and to the left of curve 3001, as illustrated by line 3010, does not cause significant adverse damage to the stepper motor. This is because the time interval T1 to T2 is relatively short, and no excessive heat builds up in the motor. However, operating the motor at power level W2 for a time interval T1 to T2 within the range 3008 above the dashed line 3004 and to the right of curve 3001, as illustrated by line 3012, causes significant adverse damage to the stepper motor. This is because the time interval T1 to T2 is relatively long, exceeds curve 3000, and excessive heat builds up in the motor, which can damage it.Operating the motor at a power level W3 and for a time interval T1 to T3 within the range 3002 below the dashed line 3004, as illustrated by line 3014, does not cause any significant adverse damage to the stepper motor. Although the time interval T1 to T3 is relatively long, no excessive heat builds up in the motor because the motor operates within the range 3002, which represents the continuous operating range of the motor.

[0202] As noted above, the controller 450 responds to the pressure signal from the pump PT to selectively apply pulse-width modulated (PMW) pulses to the stepper motor 394. This allows the motor's speed and torque to be varied as a function of the pressure signal by applying PMW pulses with a power level within the stepper motor's continuous operating range. For most or even all of the stepper motor's operation, the controller responds to the pressure signal to send PMW pulses to the stepper motor with a power level that falls within the range 3002 of the stepper motor's continuous operating range.If pressure builds up in the system, or if other factors impede the desired pressure levels, the controller is designed to respond to the pressure signal and apply PMW pulses to the stepper motor with a power that falls within the overdrive range 3006 above the dashed line 3004 and the continuous operating range of the stepper motor, and to the left of curve 3001. Thus, the controller responds to the pressure signal to selectively apply the PMW pulses to the stepper motor in order to vary the speed and torque of the stepper motor as a function of the pressure signal by applying "overdrive" PMW pulses for a period of time. The overdrive PMW pulses have an overdrive power that is higher than the continuous operating range of the stepper motor. Fig. Figure 57 shows such an embodiment.

[0203] As in Fig. As shown in Figure 57, the controller 450 has a memory that stores a speed / pressure profile 3022 of the stepper motor 394. In this embodiment, the controller responds to the pressure signal from the pump PT to selectively apply PMW pulses to the stepper motor and to vary the speed and torque of the stepper motor as a function of the pressure signal and as a function of the profile 3022 by applying PMW pulses with a power that lies both within and outside the continuous operating range of the stepper motor, as described below.

[0204] Profile 3022 has three stages: a first stage 3024, a second stage 3026, and a third stage 3028. During the first stage 3024, the PMW pulses drive the motor at approximately 1000 rpm between approximately 0 and 1000 psi. During the second stage 3026, the PMW pulses drive the stepper motor 394 at approximately 600 rpm between approximately 1000 and 2000 psi. During the third stage 3028, the PMW pulses drive the motor at approximately 200 rpm between approximately 2000 and 3000 psi. Reference numeral 3030 represents the stepper motor's throttle curve, which is also shown in Fig. Figure 58 is shown. To the left (below) of the throttle curve 3030 is an engine operating range 3034 ( Fig. 58), in which the motor operates at a speed and pressure without throttling, and to the right (above) of throttling curve 3030 is a motor throttling range 3036 in which the motor operates at a speed and pressure where the motor tends to throttle. If the motor speed at a given pressure is to the left of throttling curve 3030, the motor has a sufficient speed to push lubricant and maintain or increase the lubricant pressure. However, if the pressure at a given speed increases to such an extent that the motor operates at or to the right of throttling curve 3030, the motor tends to throttle. In other words, if the motor speed at a given pressure is to the right of throttling curve 3030, the motor speed may be insufficient to push the lubricant, and the motor tends to throttle.

[0205] In one embodiment ( Fig. 57) The rear part of each stage can include overdriving the stepper motor 394 for a period of time. As an example, consider a stepper motor driven by pulse-width modulated (PWM) pulses with a constant voltage, e.g., 24 volts, and varying duration, falling within the continuous operating range, e.g., 0–5 A. During the first stage 3024, the duration of the pulse-width modulated (PWM) pulses would be between 0 and 5 A to drive the motor at approximately 1000 rpm between approximately zero and 900 psi. At approximately 900 psi, the motor would no longer have enough power (i.e., current or torque, which is determined by the pulse duration) to increase the pressure to a desired setpoint of 1000 psi. At this point, the controller would control the driver circuitry to overdrive the motor for a period of time.This can be achieved by increasing the current supplied to the motor for a limited period of time, so that the PMW pulses would have a duration of between 5-8 A to provide sufficient power to drive the motor at approximately 1000 rpm between approximately 900 and 1000 psi.

[0206] During the second stage, the 3026 would have PWM pulses with a duration of 0-5 A to drive the 394 stepper motor at approximately 600 rpm between about 1000 and 1900 psi. At about 1900 psi, the motor would no longer have enough power (i.e., current or torque, determined by the pulse duration) to increase the pressure to a desired setpoint of 2000 psi. At this point, the controller would activate the driver circuit to overdrive the motor for a limited period. This is achieved by increasing the current supplied to the motor for a limited time, so that the PWM pulses would have a duration of 5-8 A to provide sufficient power to drive the motor at approximately 600 rpm between about 1900 and 2000 psi.

[0207] During the third stage, the 3028 would have PWM pulses with a duration of 0-5 A to drive the motor at approximately 200 rpm between approximately 2000 and 2900 psi. At approximately 2900 psi, the 394 stepper motor would no longer have enough power (i.e., current or torque, determined by the pulse duration) to increase the pressure to a desired setpoint of 3001 psi. At this point, the controller would activate the driver circuitry to overdrive the motor for a limited period. This is achieved by increasing the current supplied to the motor for a limited time, so that the PWM pulses would have a duration of 5-8 A to provide sufficient power to drive the motor at approximately 200 rpm between approximately 2900 and 3001 psi.

[0208] It is also intended that the amplitude of the PWM pulse, which is the voltage of the PWM pulse, is increased instead of the duration (current) of the pulse, in order to increase the power of the pulse and overdrive the stepper motor 394. It is also intended that the amplitude of the PWM pulse, which is the voltage of the PWM pulse, is increased in addition to the duration (current) of the pulse, in order to increase the power of the pulse and overdrive the motor.

[0209] In this way, the control system, as in Fig. 57 and Fig. Figure 58 shows that the PWM pulses are selectively applied to the stepper motor 394 to vary the speed and torque of the stepper motor as a function of the pressure signal from the pump PT by applying overdrive pulse-width modulated (PMW) pulses during a period of overdrive operation. The time period can be fixed and / or vary based on another parameter. For example, as shown in Fig. As shown in Figure 57, the specified time period would be the time required during the first stage, 3024, to increase the pressure from 900 psi to 1000 psi. Similarly, the specified time period would be the time required during the second stage, 3026, to increase the pressure from 1900 psi to 2000 psi. Likewise, the specified time period would be the time required during the third stage, 3028, to increase the pressure from 2900 psi to 3001 psi. During each stage, the following can be determined based on... Fig. 56. A maximum time for the specified overdrive operation time is set. The maximum time for a given power level is set to prevent the motor from operating in the 3008 range, as the overdrive PWM pulses have a higher overdrive power than the motor's continuous operating range.

[0210] In one embodiment described above, the stepper motor is operated in range 3006 (see W1, time T1 to T2) during an overdrive operation, and operation of the stepper motor in range 3008 (see W2, time T1 to T2) is avoided for at least a substantial period. In this way, the duration of the overdrive operation is a function of the overdrive power relative to the continuous operating range of the stepper motor. In other words, the controller selectively applies the PWM pulses to the stepper motor to vary its speed and torque as a function of the pump pressure signal PT by applying overdrive PWM pulses for a specific period. The overdrive PWM pulses have a higher overdrive power than the continuous operating range of the stepper motor, and the duration is a function of the overdrive power relative to the continuous operating range of the stepper motor.In this way, the controller applies pulse-width modulated (PWM) pulses to the stepper motor 394 such that the stepper motor speed is a first speed (e.g., 1000 rpm) when the pressure signal from the pump PT is within a first range (1 to 1000 psi) defined by the first stage 3024. Likewise, the controller applies pulse-width modulated (PMW) pulses to the stepper motor such that the stepper motor speed is a second speed (e.g., 600 rpm), which is lower than the first speed, when the pressure signal from the pump PT is within a second range (e.g., 1000 psi to 2000 psi) defined by the second stage 3026, where the second range is higher than the first. Similarly, the controller applies PMW pulses to the stepper motor such that the speed of the stepper motor is a third speed (e.g. 200 rpm) that is lower than the second speed when the pressure signal from the pump PT is within a third range (e.g.2000 psi to 3001 psi) is defined by the third level 3028, where the third range is higher than the second range.

[0211] One perspective of the profile is that the controller determines the speed of the stepper motor 394 based on the duty cycle of the pulses applied to the stepper motor. From this perspective, the controller applies overdrive PWM pulses to the stepper motor when the pressure signal from the pump PT is within a predetermined range (e.g., 900 psi to 1000 psi for the first stage 3024; 1900 psi to 2000 psi for the second stage 3026; and 2900 psi to 3001 psi for the third stage 3028), and when the motor speed is within a predetermined range. As above regarding Fig. As mentioned in section 56, the overdrive PMW pulses exhibit an overdrive power that is higher than the continuous operating range of the stepper motor.

[0212] In one embodiment, a temperature sensor is arranged adjacent to the stepper motor 394 to monitor the motor's temperature and keep it below its maximum rated temperature. The controller receives a signal from the temperature sensor indicating the motor temperature. In this embodiment, the time required to override the motor is a function of the stepper motor's temperature. Furthermore, the motor can have a maximum temperature for a given speed, torque, current, power, pressure, or RPM. The controller is configured to operate the motor only within the stepper motor's continuous operating range once the motor temperature sensor indicates that the motor temperature has reached its maximum, thus preventing motor damage.Alternatively, the controller is configured to stop the operation of the motor as soon as the motor temperature sensor indicates that the motor temperature has reached a certain temperature in order to prevent motor damage.

[0213] In other embodiments, a temperature sensor may not be required. It should be noted that the power applied to a stepper motor is proportional to the rise in the stepper motor's temperature. In this way, the processor can calculate the motor's temperature based on the power applied to the motor over time.

[0214] In one embodiment, the controller determines the speed of the stepper motor 394 based on the duty cycle of the pulses applied to the stepper motor. Alternatively or additionally, the speed can be determined by a motor speed sensor, such as a Hall sensor, which is connected to the controller and assigned to a servo motor for driving the pump stepper motor.

[0215] In one embodiment, the speed / pressure profile stored in the controller's memory is defined by at least one or more algorithms and a lookup table. For example, an algorithm for defining a speed / pressure curve, such as that shown by the dashed line 3032 from Fig. 57 is shown, stored in memory and executed by the controller.

[0216] The motor override feature described above was described in the context of lubrication systems incorporating the previously described pump unit 300. However, it is understood that the same override features can be used in lubrication systems with other pump units, such as the pump units 2500 and 2900 described above, and other pump units incorporating a stepper motor or an alternative linear position drive mechanism (e.g., the mechanism from [reference missing]). Fig. 20 or Fig. 21).

[0217] Experts will understand that the features of the individual embodiments described above can be combined with features of other embodiments. It is intended that these combinations fall within the scope of the present invention.

[0218] Embodiments of the invention can be described in the general context of data and / or computer-executable instructions, such as program modules stored on one or more tangible computer storage media and executed by one or more computers or other devices. In general, program modules include, but are not limited to, routines, programs, objects, components, and data structures that perform specific tasks or implement certain abstract data types. Aspects of the invention can also be exercised in distributed computing environments where tasks are performed by remote processing devices interconnected via a data transmission network. In a distributed computing environment, program modules can be arranged on both local and remote computer storage media, including storage devices.

[0219] During operation, computers and / or servers can execute the computer-executable instructions, such as those illustrated here for implementing aspects of the invention.

[0220] Embodiments of the invention can be implemented using computer-executable instructions. These instructions can be divided into one or more computer-executable components or modules on a tangible, computer-readable storage medium. Aspects of the invention can be implemented using any number and arrangement of such components and modules. For example, aspects of the invention are not limited to specific computer-executable instructions or the specific components or modules shown in the figures and described herein. Other embodiments of the invention may include different computer-executable instructions or components with more or fewer functions than those shown and described herein.

[0221] The order in which the operations are carried out in the embodiments of the invention presented and described herein is not crucial, unless otherwise specified. That is to say, unless otherwise specified, the operations can be carried out in any order, and embodiments of the invention may include additional or fewer operations than those disclosed herein. For example, it is intended that carrying out a particular operation before, simultaneously with, or after another operation falls within the scope of certain aspects of the invention.

[0222] When introducing elements of aspects of the invention or its embodiments, the articles "a", "an", "an", "a", "one", "of", "the", "the", "the", "the", and "of" are intended to indicate that one or more of the elements are meant. The terms "comprise", "include", and "have" are meant inclusively and mean that, in addition to the elements listed, further elements may also be present.

[0223] In light of the foregoing, it becomes clear that several aspects of the invention are achieved and other advantageous results are obtained.

[0224] It is possible that not all components shown or described will be required. Furthermore, some implementations and embodiments may include additional components. Variations in the arrangement and type of components are possible without deviating from the spirit or scope of the stated claims. Additionally, different or fewer components may be provided, and components may be combined. Alternatively or additionally, a component may be implemented by multiple components.

[0225] The summary and abstract are intended to enable the reader to quickly gain an understanding of the nature of the technical disclosure. They are submitted on the condition that they will not be used to interpret or limit the scope or meaning of the claims.

[0226] The foregoing description illustrates the invention by means of examples, but not in a limiting manner. Where two or more elements are shown, it is understood that the invention may include two or more elements. This description enables those skilled in the art to manufacture and use the invention and describes several embodiments, adaptations, modifications, alternatives, and uses of the invention, including what is currently considered the best way to carry out the invention. Furthermore, it is understood that the application of the invention is not limited to the details of the construction and arrangement of the components listed in the following description or shown in the drawings. The invention allows for other embodiments and can be exercised or carried out in different ways.It is also understood that the language and terminology used herein serve the purpose of description and are not to be understood as restrictive.

[0227] The detailed description of aspects of the invention has made it clear that modifications and adaptations are possible without deviating from the scope of aspects of the invention defined in the accompanying claims. Since various changes can be made to the above-mentioned designs, products, and processes without deviating from the scope of aspects of the invention, it is intended that all points contained in the above description and shown in the accompanying drawings are to be interpreted as illustrative and not as limiting.

Claims

[1] Device (300, 2500, 2900) for pumping lubricant, comprising: a container (304, 2504, 2930) with a tank (2518, 2932) with a side wall (310, 2520, 2936) and with an interior (2536) for receiving lubricant, a stirrer (320, 2600, 2940) that is rotatable in the container; a pressure lubrication mechanism (330, 2630) on the stirrer which is operational when the stirrer is rotated to exert a pressure force that forces lubricant from the container along a flow path (2586) defined by a tubular channel extending away from an inlet opening of the tubular channel; a pump housing (306, 2506, 2902) with an upper wall (2540, 2950), wherein the upper wall (2540, 2950) defines a bottom of the interior (2536) of the container to be in contact with the lubricant contained inside the container (304, 2504, 2930), wherein the upper wall (2540, 2950) includes an opening (2582, 2954) which forms the inlet opening of the tubular channel, a pump located under the reservoir to pump lubricant from the reservoir to a lubricant distribution system; wherein the pump comprises a cylinder (334, 2508) with a cylinder inlet (2570, 2920) aligned with the opening in the upper wall of the pump housing and in fluid communication with the interior of the container (304, 2504, 2930) via the flow path (2586) defined by the tubular channel, a cylinder bore (338, 2566, 2910) and a piston (384, 1230, 1330, 2512, 2908) which is movable in the cylinder bore, which is arranged at an outlet opening of the flow path defined by the tubular channel, by a pump stroke and a return stroke, wherein the cylinder inlet has a surface (2574) in sealing engagement with an opposite surface (2578) of the upper wall of the pump housing to separate the tubular channel from the upper wall (2540, 2950) to seal the cylinder inlet; wherein the cylinder bore is connected to the interior of the container via the flow path (2586) defined by the tubular channel, whereby the rotation of the stirrer causes the pressure lubrication mechanism to exert a pressure force on the stirrer, which pushes the lubricant along the flow path defined by the tubular channel, such that the movement of the piston during the return stroke generates a reduced pressure in the cylinder bore, which exerts a tensile force on the lubricant along the flow path defined by the tubular channel, wherein the pressure and tensile forces together move the lubricant along the flow path defined by the tubular channel from the container (304, 2504, 2930) into the cylinder bore; wherein the flow path defined by the tubular channel (2586) is a generally straight flow path with a length of less than 7.62 cm. [2] Device (300, 2500, 2900) according to claim 1, wherein the flow path (2586) defined by the tubular channel from the interior (2536) of the container (304, 2504, 2930) to the cylinder bore (338, 2566, 2910) is sealed against atmospheric pressure. [3] Device (300, 2500, 2900) according to claim 1, wherein the tank (2518, 2932) has no bottom wall. [4] Device (300, 2500, 2900) according to claim 1, wherein the lubricant flow path from an upper end of the flow path defined by the tubular channel (2586) to a lower end of the flow path defined by the tubular channel is generally vertical. [5] Device (300, 2500, 2900) according to claim 6, wherein the cylinder inlet has an inlet channel (340, 2570, 2920) having an elongated shape in cross-section, wherein the elongated shape has a main dimension generally transverse to a longitudinal centerline of the cylinder bore (338, 2566, 2910) and a subdimension generally parallel to the longitudinal centerline of the cylinder bore. [6] Device (300, 2500, 2900) according to claim 7, wherein the main dimension is approximately equal to the diameter of the cylinder bore (338, 2566, 2910) at the junction of the inlet channel (340, 2570, 2920) and the cylinder bore, and wherein the subdimension is smaller than the diameter of the cylinder bore. [7] Device (300, 2500, 2900) according to claim 8, wherein the flow path (2586) defined by the tubular channel has a section with an elongated shape in cross-section, wherein the elongated shape has a main dimension generally transverse to a longitudinal centerline of the cylinder bore (338, 2566, 2910) and a subdimension generally parallel to the longitudinal centerline of the cylinder bore. [8] Device (300, 2500, 2900) according to claim 9, wherein the main dimension is approximately equal to a diameter of the cylinder bore (338, 2566, 2910) at the junction of the inlet bore and the cylinder bore, and wherein the subdimension is smaller than the diameter of the cylinder bore. [9] Device (300, 2500, 2900) according to claim 1, wherein the flow path (2586) defined by the tubular channel has a channel (340, 2570, 2920) with an open upper end for direct entry of the lubricant from the interior of the tank into the channel and an open lower end for direct exit of the lubricant from the channel into the cylinder bore (338, 2566, 2910). [10] Device (300, 2500, 2900) according to claim 11, wherein the channel (340, 2570, 2920) is closed except for its upper and lower ends. [11] Device (300, 2500, 2900) according to claim 1, wherein the pressure lubrication mechanism (330, 2630) comprises a pressure lubrication element (330a, 2632) on the stirrer (320, 2600, 2940) having an inclined surface (2636) to force lubricant along the flow path (2586) defined by the tubular channel while the stirrer rotates. [12] Device (300, 2500, 2900) according to claim 1, further comprising a control (450, 2308) programmed to operate the stirrer (320, 2600, 2940) and the pump simultaneously, whereby the tensile and compressive forces act simultaneously to move the lubricant along the flow path (2586) defined by the tubular channel into the cylinder bore (338, 2566, 2910). [13] Device (300, 2500, 2900) according to claim 1, further comprising a linear drive mechanism (390, 1200, 1300, 2740) for moving the piston (384, 1230, 1330, 2512, 2908), wherein the linear drive mechanism comprises a stepper motor (394, 2742, 2914). [14] Device (300, 2500, 2900) according to claim 1, further comprising a first motor (326, 2616) for driving the stirrer (320, 2600, 2940) and a second motor (394, 1204, 1370, 2742, 2914) which is controlled independently compared to the first motor, for driving the pump. [15] Device (300, 2500, 2900) according to claim 1, further comprising a controller (450, 2308) configured to operate the pump, wherein the controller is configured to pump a predetermined volume of lubricant and wherein the controller operates the pump for a predetermined period of time or for a predetermined number of pump strokes to pump the predetermined volume of lubricant. [16] Device (300, 2500, 2900) according to claim 1, wherein the pump housing (306, 2506, 2902) has a side wall (2542, 2952) hanging down from the top wall and a bottom wall (2546), wherein the top wall, side wall and bottom wall of the pump housing enclose the pump. [17] Device (300, 2500, 2900) according to claim 16, which further comprises a linear drive mechanism (390, 2740) for moving the piston (384, 2512, 2908), wherein the top wall, side wall and bottom wall of the pump housing enclose the drive mechanism.

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