Compressor Lubrication Monitoring for Bearing and Shaft Failure Prediction
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Solution Overview
Problem
Existing compressor systems lack effective methods to predict failures in bearings and drive shafts due to insufficient lubrication, leading to potential seizure and inoperability before they can be detected.
Innovation Solution
A compressor system with an oil supply passage that prioritizes lubrication to bearings and drive shafts, using discharge gas temperature as an index to predict impending failures by detecting changes in lubrication state, and a failure prediction unit to adjust operating conditions to prevent severe damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubricating oil is supplied to both the compression section and sliding portions simultaneously, then the compression section receives adequate lubrication, but the sliding portions of the drive shaft and bearing may suffer from insufficient lubrication leading to failure
Solution Approach 1:
The oil supply system is designed with different oil supply ratios for different components. The sliding portions of the drive shaft and bearing receive a higher proportion of lubricating oil compared to the compression section, creating localized quality enhancement where it is most needed to prevent failure.
Solution Approach 2:
The system performs preliminary lubrication of the sliding portions by prioritizing oil supply to these critical components before they undergo severe wear or failure. This advance lubrication prevents the seizure and failure that would otherwise occur during operation.
2Reliability
If the oil supply ratio to the compression section is increased, then the compression section is adequately lubricated, but the sliding portions receive insufficient lubrication causing potential failure
Solution Approach 1:
The lubricating oil distribution is optimized by allocating a higher quantity of oil to the sliding portions of the drive shaft and bearing, while maintaining adequate supply to the compression section. This localized quality enhancement ensures critical components receive sufficient lubrication to prevent failure.
Solution Approach 2:
The system changes the oil supply parameters by adjusting the oil supply ratio dynamically. The sliding portions receive a higher proportion of the total lubricating oil quantity, transforming the distribution parameter to prioritize components most susceptible to lubrication-deficiency failure.
3Reliability
If no failure prediction mechanism is implemented, then the system structure remains simple, but failures in bearings and drive shafts occur without warning leading to seizure
Solution Approach 1:
The failure prediction mechanism continuously monitors the lubrication state of the sliding portions and provides feedback about the risk of failure. This feedback loop enables early detection of deteriorating conditions, allowing preventive maintenance before seizure occurs.
Solution Approach 2:
The system performs preliminary detection of failure conditions by monitoring lubrication state parameters before actual failure occurs. This advance warning enables preventive measures to be taken, avoiding the seizure and failure of the bearings and drive shafts.
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
Early detection of potential failures in bearings and drive shafts allows for preventive measures, reducing the risk of seizure and extending the compressor's operational lifespan.
Implementation Method 1
lubricating oil being supplied from a common oil supply source to the compression section and to a sliding portion of the drive shaft and the bearing
Implementation Method 2
a failure prediction unit configured to predict the failure of the bearing and the drive shaft based on a change in an index indicating deterioration of sealability of the compression chamber
Data Source
AI summary
A compressor system includes a compressor, and a prediction device configured to predict a failure of a bearing and a drive shaft of the compressor. The compressor includes a motor, a compression section, the drive shaft, and the bearing. Lubricating oil is supplied from a common oil supply source to the compression section and to a sliding portion of the drive shaft and the bearing. The prediction device includes a failure prediction unit configured to predict the failure of the bearing and the drive shaft based on a change in an index indicating deterioration of sealability of the compression chamber.