Gear Lubrication Pump Control via Downstream Pressure Feedback
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Solution Overview
Problem
Ensuring proper lubrication of mechanical gears under varying conditions, such as temperature changes, is challenging due to viscosity variations affecting lubrication fluid flow and its ability to maintain a lubricating film between metal parts, especially in wind turbines where temperatures can range from −40 to +85 degrees Celsius.
Innovation Solution
A pressure-controlled lubrication system is implemented by placing a lubrication fluid pressure sensor downstream of the pump, allowing the output power to be adjusted based on measured pressure, which compensates for changes in viscosity due to temperature or other factors, ensuring consistent lubrication film formation between moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a rotational movement of gear parts is used to drive the lubrication pump, then the device complexity is reduced, but the reliability deteriorates due to delay at startup before sufficient lubrication fluid reaches critical moving parts
Solution Approach 1:
The control unit activates the lubrication pump before the gearwheels start rotating, ensuring that lubrication fluid is delivered to critical moving parts from the beginning of operation. This preliminary action eliminates the startup delay inherent in rotation-driven pump systems.
2Reliability
If a dedicated power source is used to drive the lubrication pump, then the reliability of lubrication delivery is improved, but the device complexity increases due to additional control requirements
Solution Approach 1:
The lubrication pump control is integrated with the existing control unit that manages other wind turbine operations. This merging of control functions allows the pump to be activated as part of the controlled startup sequence without requiring a separate dedicated control system.
Solution Approach 2:
The control unit is designed to perform multiple functions including managing the lubrication pump, gearwheel rotation, and other wind turbine operations. This multi-functionality eliminates the need for separate control systems while maintaining reliable lubrication delivery.
3Reliability
If the lubrication pump output power is increased to compensate for high temperature and low viscosity, then the lubrication film capability is maintained, but the use of energy increases
Solution Approach 1:
The lubrication pump output power is dynamically adjusted based on real-time viscosity measurements. When viscosity is low (high temperature), the pump power is increased to maintain lubrication film capability. When viscosity is high (low temperature), the pump power is reduced. This dynamic adjustment maintains reliable lubrication while optimizing energy consumption.
Solution Approach 2:
A viscosity measurement system provides feedback to the control unit, which adjusts the lubrication pump power accordingly. This closed-loop feedback ensures that the pump delivers appropriate power to maintain lubrication film capability under varying temperature and viscosity conditions while avoiding unnecessary energy consumption.
4Use of energy by moving object
If the lubrication pump output power is decreased to match low temperature and high viscosity conditions, then the use of energy is reduced, but the lubrication film capability deteriorates
Solution Approach 1:
The lubrication pump output power is dynamically adjusted based on real-time viscosity measurements. When viscosity is high (low temperature), the pump power is initially set appropriately, but can be increased if viscosity decreases during operation to maintain lubrication film capability.
Solution Approach 2:
The viscosity measurement system provides continuous feedback to the control unit, which adjusts the pump power in real-time. This ensures that even when starting with high viscosity conditions, the system can respond to viscosity changes and maintain adequate lubrication film capability while optimizing energy 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 solution effectively maintains a stable lubrication film across varying conditions, indicating system health through output power changes, and can be easily integrated with other control functionalities and scaled for different gear sizes, ensuring reliable gear operation.
Implementation Method 1
placing a lubrication fluid pressure sensor downstream of the lubrication pump and by using the measured pressure at least partly to vary the output power of the lubrication pump
Implementation Method 2
The gear stage(s) and the bearings need lubrication, for which purpose the gear unit typically comprises a lubrication pump configured to circulate lubrication fluid through the gear stages and bearings
Implementation Method 3
temperatures ranging from −40 to over +85 degrees centigrade may occur within the gear, with significant effects on the viscosity of the lubrication fluid. Changes in viscosity affect the way in which the lubrication fluid flows through the lubrication channels
Data Source
AI summary
A gear lubrication arrangement comprises a lubrication pump for circulating lubrication fluid. A power source coupled to the lubrication pump drives the lubrication pump, and a controller controls an output power of the lubrication pump. The gear lubrication arrangement comprises a pressure sensor disposed down-stream of the lubrication pump The pressure sensor is configured to measure a pressure of the lubrication fluid and to produce a pressure indication signal representative thereof. The controller is arranged to vary the output power of the lubrication pump at least partly on the basis of the pressure indication signal.