Piston Compressor Lubrication Film Thickness Control
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Solution Overview
Problem
Existing piston compressor lubrication systems often result in overlubrication, leading to increased wear on components, reduced lifespan, and higher operating costs due to excessive lubricant consumption and the need for additional equipment to manage excess lubricants.
Innovation Solution
A lubrication system that includes a lubricant sensor, such as an ultrasonic sensor, to measure the lubricating film thickness on the cylinder running surface, and a control unit that adjusts the lubricant amount based on the measured film state, ensuring the precise amount of lubricant is applied during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a specified lubricant quantity is used based on empirical data or simplified calculation models, then the lubrication system is simple to operate, but overlubrication occurs leading to increased wear on components and reduced service life
Solution Approach 1:
The patent implements a feedback mechanism where a lubricant sensor continuously monitors the lubricating film thickness on the cylinder running surface and provides real-time information to the control unit. The control unit adjusts the lubricant injection quantity based on this feedback, creating a closed-loop control system that prevents overlubrication while maintaining simple operation through automated control.
Solution Approach 2:
The patent replaces manual or empirical determination of lubricant quantities with an automated sensor-based measurement system. The lubricant sensor uses ultrasonic measurement technology to non-contactedly detect film thickness, substituting mechanical measurement methods with acoustic field-based detection, thereby enabling precise control without complex mechanical adjustment mechanisms.
2Reliability
If excessive lubricant is supplied to ensure adequate lubrication, then component wear is reduced, but lubricant consumption increases and operating costs rise
Solution Approach 1:
The patent dynamically changes the lubricant injection quantity parameter based on real-time measurements of lubricating film thickness. The control unit adjusts the injection quantity to match the actual lubrication needs, transitioning from fixed excessive injection to variable precise injection, thereby reducing lubricant consumption while maintaining adequate film thickness for wear protection.
Solution Approach 2:
The patent applies partial action by supplying only the necessary amount of lubricant rather than excessive quantities. The sensor-based control enables the system to provide just enough lubricant to maintain adequate film thickness, eliminating the need for excessive lubricant supply and reducing associated costs.
3Loss of substance
If a lubricant sensor and control unit are added to measure and control lubricant quantity, then lubricant consumption is reduced, but device complexity increases
Solution Approach 1:
The patent uses ultrasonic measurement technology to replace complex mechanical measurement and control mechanisms. The lubricant sensor employs acoustic field-based detection to measure film thickness non-contactedly, simplifying the overall system structure compared to mechanical sensors or visual inspection methods, while enabling precise lubricant quantity control.
4Device complexity
If conventional lubrication systems are used without real-time measurement, then the system structure remains simple, but component wear increases due to overlubrication
Solution Approach 1:
The patent introduces a feedback mechanism where the lubricant sensor continuously monitors lubricating film thickness and provides real-time information to the control unit. This feedback loop enables the system to detect and correct overlubrication conditions, protecting components from wear while adding only minimal structural elements (sensor and control unit).
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 solution reduces lubricant consumption, prevents overlubrication, and extends the lifespan of compressor components, thereby lowering operational costs and improving compressor availability.
Implementation Method 1
the lubricant sensor is an ultrasonic sensor
Data Source
Figure 1
Figure 2~3b
Figure 4
AI summary
To prevent over-lubrication of the cylinders (2) in a piston compressor (1) and to reduce the amount of lubricant to a level required for operation, a lubrication system with a lubrication system control unit (14) is provided according to the invention, in which at least one lubricant sensor (15) is provided for detecting a lubricant film measurement parameter (S) representative of a lubricant film thickness (11) on the cylinder running surface of the cylinder (2), wherein the lubrication system control unit (14) is configured to operate the lubrication system at least once in a predetermined calibration operating mode during the operation of the piston compressor (1) and to determine a lubricant film condition value (SZ) on the basis of the lubricant film measurement parameter (S) detected during the execution of the calibration operating mode, and wherein the lubrication system control unit (14) is configured toAfter the calibration operating mode has ended, the amount of lubricant to be introduced during operation of the piston compressor (1) is to be controlled depending on the determined lubricant film condition value (SZ).