Grease Gun Sensor for Accurate Lubricant Dispensing
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Solution Overview
Problem
Existing grease guns lack accurate sensing capabilities, leading to incorrect grease usage calculations due to air pockets and continued operation when cartridges are empty, resulting in cavitation.
Innovation Solution
A system with a sensor to measure the force applied to the piston, using a controller to determine the amount of lubricant ejected based on current differences between upstroke and downstroke motor currents, and providing alerts for loss of prime and empty cartridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If stroke-counting capabilities are used to determine grease usage, then grease delivery can be tracked, but the measurements become inaccurate when air pockets are present
Solution Approach 1:
The patent replaces the mechanical stroke-counting method with an electrical measurement system. A sensor measures the current drawn by the motor during piston operation, and the controller analyzes current differences between upstroke and downstroke to determine whether grease was actually delivered. This electrical measurement system is insensitive to air pockets, resolving the contradiction between being able to track grease delivery and maintaining accuracy when air is present.
2Productivity
If the piston continues to operate when the cartridge is empty, then the motor keeps running, but cavitation occurs
Solution Approach 1:
The patent implements a feedback system where the sensor continuously monitors motor current and the controller analyzes the current characteristics to detect when the cartridge is empty. When no grease is being delivered (indicated by absence of current difference between strokes), the system provides feedback to stop motor operation, preventing cavitation while allowing continuous operation when grease is available.
3Device complexity
If simple stroke counting is used, then the device complexity is low, but the sensing capability is insufficient
Solution Approach 1:
The patent replaces complex mechanical sensing mechanisms with a simple electrical current measurement system. The sensor measures motor current, and the controller analyzes current differences between piston strokes to detect lubricant ejection. This electrical approach achieves precise measurement of lubricant delivery without adding significant mechanical complexity to the device.
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
Accurately measures and dispenses lubricant, preventing cavitation and ensuring correct grease usage calculations by distinguishing between effective and ineffective piston strokes.
Implementation Method 1
a sensor configured to measure a current drawn by the motor during operation
Data Source
AI summary
Systems, methods, and apparatus for dispensing a lubricant are provided, in which, for example, the apparatus includes a chamber having an inlet through which the lubricant is received and an outlet through which the lubricant is ejected. The apparatus also includes a piston movably positioned in the chamber to take lubricant into the chamber and eject it therefrom. The apparatus further includes a sensor configured to take a measurement of a condition related to a force applied to the piston to move the piston in the chamber. The apparatus additionally includes a controller coupled with the sensor so as to receive data related to the measurement from the sensor. The controller is configured to determine, using the measurement, an amount of lubricant ejected by the piston.