Kidney Loop Oil Temperature Control for Startup Lubrication
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Solution Overview
Problem
Mechanical equipment faces issues due to lubricating oil being below the desired startup temperature, resulting in undesirable viscosity that increases horsepower draw and prevents complete oil circulation, while excessively viscous oil fails to reach system components, leading to direct contact and inadequate lubrication.
Innovation Solution
A lubricating oil system incorporating a kidney loop with a reservoir, pump, cooler, heater, and control system, including a thermostat, which monitors temperature and adjusts the flow rate by circulating oil through the heater or cooler to maintain a setpoint temperature, optimizing viscosity between 0 to 80 centipoise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If lubricating oil is circulated at low temperature, then the system can start up, but the oil viscosity is undesirable (0-80 centipoise) causing high horsepower draw and incomplete circulation
Solution Approach 1:
The system performs preliminary heating of the lubricating oil through a heater before the main circulation begins. The kidney loop pump circulates oil through the heater to raise its temperature above the minimum startup temperature, ensuring optimal viscosity (above 80 centipoise) is achieved before full system operation, thereby preventing high horsepower draw and incomplete circulation
Solution Approach 2:
The system changes the temperature parameter of the lubricating oil from below minimum startup temperature to above minimum startup temperature using the heater. This parameter change transforms the oil viscosity from undesirable (0-80 centipoise) to optimal range, resolving the contradiction between circulation capability and energy consumption
2Ease of operation
If lubricating oil temperature is increased to reduce viscosity, then circulation improves, but the oil may become too thin to reach all system components
Solution Approach 1:
The system uses a thermostat to continuously monitor the lubricating oil temperature and provides feedback to the control system. Based on this feedback, the control system adjusts the heater operation to maintain oil temperature within the optimal range (above minimum startup temperature but not excessively high), ensuring both proper circulation and adequate viscosity for component lubrication
Solution Approach 2:
The system precisely controls the temperature parameter within an optimal range rather than simply increasing it. This controlled parameter change ensures the oil viscosity remains in the appropriate range to reach all system components while maintaining circulation capability, preventing both incomplete circulation and insufficient lubrication
3Temperature
If a heating system is added to warm the oil, then startup temperature is achieved, but the system complexity increases
Solution Approach 1:
The heating function is merged into the existing kidney loop circulation system. The heater is integrated with the kidney loop pump and reservoir, allowing the same circulation infrastructure to serve both cooling and heating functions. This merging approach achieves temperature control without proportionally increasing system complexity
Solution Approach 2:
The kidney loop system is designed with multi-functionality, serving both as a cooling circulation system and a heating circulation system. By adding the heater and thermostat control, the system gains temperature regulation capability while utilizing existing pump and piping infrastructure, thereby limiting the increase in overall system complexity
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
The system effectively regulates lubricating oil temperature to achieve optimal viscosity, reducing horsepower consumption and ensuring proper lubrication by maintaining the oil within a desired temperature range, thus preventing mechanical damage and improving system efficiency.
Implementation Method 1
circulating the lubricating oil through the heater
Implementation Method 2
circulating oil through the heater or cooler to maintain a setpoint temperature
Data Source
AI summary
A lubricating system includes a kidney loop. The kidney loop includes a reservoir and a kidney loop pump, the kidney loop pump in fluid connection with the reservoir. The kidney loop also includes a cooler, the cooler in fluid connection with the kidney loop pump and a heater, the heat in fluid connection with the kidney loop pump. Further, the kidney loop includes a kidney loop motor, the kidney loop motor in electrical connection with the kidney loop pump and a control system, the control system in electrical connection with the kidney loop motor.