Minimal Lubrication Device with Pressure Compensator
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Solution Overview
Problem
Current air/oil lubrication devices are sensitive to pressure variations at the lubrication point, leading to inconsistent oil delivery and require pressurized oil reservoirs that need to be depressurized for topping up, making them inefficient and impractical for applications with varying pressures.
Innovation Solution
The air/oil lubrication device incorporates a high-pressure pump connected to a modular mixer system with a compensator device that maintains a constant oil flow through a needle valve, using a combination of pressurized oil and compressed air, and includes a solenoid valve and pilot pistons to regulate oil quantity independently of user-side pressure, along with a vortex tube for temperature adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a pressurized oil reservoir is used to deliver oil through a needle valve, then oil can be delivered to the lubrication point, but the system becomes sensitive to pressure variations at the lubrication point causing inconsistent oil delivery
Solution Approach 1:
The patent introduces a compensator device as an intermediary between the pressurized oil reservoir and the needle valve. This compensator includes a piston that responds to pressure variations at the lubrication point and automatically adjusts the oil flow to compensate for these variations, thereby maintaining consistent oil delivery despite pressure changes in the system.
Solution Approach 2:
The compensator device implements a feedback mechanism where pressure variations at the lubrication point are detected and automatically compensated for by adjusting the oil flow through the needle valve. The system continuously monitors and adjusts the oil delivery to maintain consistency, creating a closed-loop control system that eliminates the sensitivity to pressure variations.
2Power
If a pressurized oil reservoir is used, then oil can be delivered under pressure, but the system must be halted and depressurized each time the lubricant needs to be topped up
Solution Approach 1:
The patent enables continuous operation of the lubrication system by implementing a design where oil can be topped up without halting the system. The compensator device and reservoir system are designed to maintain pressure and continue delivering oil during the topping-up process, eliminating downtime and ensuring continuous useful action.
Solution Approach 2:
The system is designed with a reservoir capacity and refilling mechanism that allows preliminary topping-up actions to be performed during normal operation. The compensator device maintains system pressure during refilling, enabling the topping-up action to occur without interrupting the lubrication function.
3Length of moving object
If compressed air is used to transport pressurized oil, then oil can be delivered to remote lubrication points, but the oil quantity injected into the flow decreases when user-side pressure increases
Solution Approach 1:
The compensator device implements feedback control that monitors pressure variations in the transport line and at the lubrication point. When user-side pressure increases and tends to reduce oil injection quantity, the compensator automatically adjusts the oil flow to compensate, maintaining consistent oil delivery regardless of pressure changes or transport distance.
Solution Approach 2:
The system dynamically adjusts flow parameters through the compensator device to compensate for changes in transport distance and pressure conditions. By changing the flow parameters in response to pressure variations, the system maintains optimal oil injection quantity regardless of the distance oil must be transported or the pressure conditions at the destination.
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 ensures precise and consistent oil delivery regardless of pressure fluctuations and eliminates the need to halt the system for oil topping, enhancing performance and cost-effectiveness by maintaining a stable oil flow and allowing for flexible air sourcing.
Implementation Method 1
a conduit feeding the lubricant fluid from the reservoir to a suction port of a high pressure pump (6)
Implementation Method 2
a vortex tube for temperature adjustment
Implementation Method 3
the oil quantity flowing through an orifice (needle valve) depends on the pressure difference between the conduit into which said oil is delivered and the initial fluid pressure
Data Source
Figure 1~3
Figure 2
Figure 4
AI summary
A minimal lubrication device (1) comprising a lubricant fluid storage reservoir (2) and a pump (6) for said lubricant, said pump (6) being a high pressure pump with a delivery side connected to at least one modular element (M) arranged to mix a compressed air flow with said lubricant, said modular element (M) presenting a mixer element fed with a compressed air flow into which an outlet opens of a needle flow regulator fed by the lubricant originating from the pump. The module (M) comprises a compensator device which maintains the oil quantity dispensed by the flow regulator constant even if the pressure on the user side changes.