Sensor-Guided Clipping Machine Lubrication for Bearing Wear Control
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Solution Overview
Problem
Existing clipping machines face inefficiencies in lubrication, leading to increased wear and potential damage due to inconsistent lubricant application, which can result in excessive consumption, contamination, and premature component failure.
Innovation Solution
A clipping machine with a control unit that adjusts lubrication schedules based on real-time sensor data from drivable components, optimizing lubricant delivery based on load and operating conditions to ensure adequate lubrication without excess.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual lubrication is performed at each lubricating fitting, then the operator can control lubricant application, but the process is time-consuming and prone to insufficient lubrication at difficult-to-reach bearings
Solution Approach 1:
The system enables automatic lubrication where the machine lubricates itself through a central lubricating unit that automatically delivers lubricant to multiple bearings simultaneously, eliminating the need for manual intervention and ensuring consistent lubrication without time loss
Solution Approach 2:
A single central lubricating unit serves multiple lubricating points throughout the machine through a network of lubricating pipes, allowing one device to perform the function of lubricating numerous bearings that would otherwise require individual manual attention
2Loss of time
If a central lubricating unit is used to lubricate all bearings, then lubrication time is reduced, but some bearings may receive insufficient lubricant while others receive excessive lubricant
Solution Approach 1:
The system incorporates sensors that monitor lubricant consumption and bearing conditions in real-time, providing feedback to the control unit which adjusts the lubrication schedule and dosage dynamically to ensure each bearing receives the precise amount of lubricant it needs
Solution Approach 2:
The lubrication system transitions from a static, uniform lubrication approach to a dynamic system where lubricant delivery is continuously adjusted based on real-time sensor data about bearing load, speed, and lubricant consumption patterns
3Reliability
If excessive lubricant is provided to bearings, then lubrication adequacy is ensured, but lubricant consumption increases and may cause contamination of products
Solution Approach 1:
Sensors monitor lubricant consumption at each bearing and provide real-time data to the control unit, which adjusts the lubrication dosage to match actual needs, preventing both over-lubrication and under-lubrication while minimizing waste
Solution Approach 2:
The system dynamically changes lubrication parameters such as dosage, frequency, and timing based on bearing operating conditions including load, speed, and temperature, ensuring optimal lubrication efficiency and minimizing excess lubricant consumption
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces wear, minimizes energy consumption, prevents lubricant waste, and maintains product quality by ensuring precise lubrication according to component needs, thereby extending machine lifespan and reducing operational costs.
Implementation Method 1
a pump unit, the lubricating device is connected to at least one first lubricating point of the at least one first drivable component of the clipping machine by a lubricating pipe through which lubricant is delivered to the lubricating point by the pump unit
Implementation Method 2
For preventing or minimizing wear and damages to said mechanical assemblies, a suitable lubricant is provided to the contact surfaces and counter surfaces or bearings
Data Source
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AI summary
The present invention relates to a clipping machine (CM) as well as a method for controlling a clipping machine (CM) for producing sausage-shaped products (S) by filling a filling material into a tubular or bag-shaped packaging casing (M), having at least one first drivable component (100), at least one drive device (300, 300a) for driving said at least one first drivable component (100), a control unit (CU) for controlling the operation of said at least one drive device (300) of said at least one first drivable component (100), and at least a first sensor unit (SU1) associated with the at least one first drivable component (100) and coupled to the control unit (CU). The clipping machine (CM) further comprises a lubricating device (400) including a supply (410) of lubricant and a pump unit (420), the lubricating device (400) being connected to at least one first lubricating point (102) of the at least one first drivable component (100) of the clipping machine (CM), by a lubricating pipe (422, 434) through which lubricant is delivered to the at least one first lubricating point (102) by the pump unit (420). The lubricating device (400) being controlled by the control unit (CU), wherein the control unit (CU) is adapted to operate the lubricating device (400) according to a predefined lubricating schedule for executing lubricating events to the at least one first drivable component (100). The control unit (CU) is adapted to vary the lubricating schedule upon a signal of the first sensor unit (SU1) indicating specific operating conditions of the at least one first drivable component (100).