Lubricant Injector with Electromagnetic Flow Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lubrication systems for piston machines, particularly 'pump-to-point' systems, face inaccuracies in setting low lubrication quantities, leading to excessive lubricant consumption, operational costs, and environmental issues due to high oil quantities, which are not precisely controlled or monitored.
Innovation Solution
A lubricant injector with a permanent magnet and flow sensor, positioned between the inlet conduit and needle valve, uses electromagnetic induction to measure lubricant flow independently of viscosity and temperature, allowing for precise control and minimal leakage, with a central control unit adjusting lubricant delivery based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pump-to-point lubrication system is used, then lubrication can be provided to multiple points, but the setting of low lubrication quantities is excessively inaccurate
Solution Approach 1:
The patent replaces mechanical flow measurement and control mechanisms with electromagnetic induction-based flow sensing. The permanent magnet attached to the needle valve interacts with measuring coils to generate voltage signals proportional to flow quantity, eliminating the need for complex mechanical metering devices and enabling precise digital measurement of lubrication quantities.
Solution Approach 2:
The patent implements feedback control by continuously measuring the actual lubrication quantity delivered through the flow sensor and comparing it with the target quantity. The control unit adjusts the needle valve position based on this feedback to achieve precise dosing, resolving the inaccuracy problem while maintaining system simplicity.
2Reliability
If a pressure-controlled lubrication system with separate valves is used, then lubrication quantity can be controlled, but leakage recirculation and overpressure-reducing lines are required causing reliability problems
Solution Approach 1:
The patent extracts and eliminates the problematic leakage recirculation and overpressure-reducing lines from the system. By using a needle valve with precise electromagnetic control and flow measurement, the system achieves accurate lubrication delivery without requiring backup leakage paths, thereby improving reliability while reducing structural complexity.
Solution Approach 2:
The system uses the flow sensor to monitor actual lubrication delivery and automatically adjusts the needle valve to compensate for variations, making the system self-regulating and eliminating the need for separate leakage management components.
3Reliability
If high lubrication rates are provided to ensure adequate lubrication, then reliable operation is achieved, but operating costs increase due to high lubricant consumption
Solution Approach 1:
The patent implements dynamic lubrication control by continuously measuring actual flow quantity and adjusting the needle valve position in real-time based on load conditions and run-in processes. This enables the system to deliver precisely the right amount of lubricant needed at each moment, avoiding both over-lubrication and under-lubrication, thereby maintaining reliability while minimizing lubricant consumption.
4Reliability
If high lubrication rates are used, then adequate lubrication is ensured, but environmental impact increases due to high oil quantities in gas
Solution Approach 1:
The patent applies partial action by delivering only the necessary amount of lubricant required for effective lubrication rather than excessive quantities. The flow sensor and control system ensure that lubrication is sufficient for reliable operation while minimizing the amount of lubricant that could contaminate the gas, thereby reducing environmental impact without compromising lubrication effectiveness.
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 enables precise, efficient, and adaptive lubricant delivery to each lubrication point, reducing lubricant consumption, minimizing errors, and optimizing lubrication according to load conditions and run-in processes, thereby reducing costs and environmental impact.
Implementation Method 1
The movement of the permanent magnet generates in the measuring coil (or in the plurality of measuring coils), by means of electromagnetic induction, a voltage, which may be evaluated by the electronic unit for determining the flow quantity
Data Source
AI summary
An invention refers to a lubricant injector, a lubrication system and a method for providing lubricant for a piston machine. The lubricant injector is provided with a lubricant inlet conduit and an outlet opening, through which a lubricant is supplied to an inner space to be lubricated of a piston machine. The outlet opening may be selectively opened and closed by means of a needle valve, which is actuated by a magnet coil. The lubricant injector has a flow sensor suitable for determining the quantity of lubricant delivered through the outlet opening.