Lubrication System Dual Pressure Sensor Control
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Solution Overview
Problem
Conventional lubrication systems for mobile machines are prone to inaccuracy in determining pressure at injectors, leading to premature failure and damage, especially when viscosity increases or improper lubricants are used, and they often fail to prevent excessive pump pressure due to reliance on single pressure sensors and pressure regulators.
Innovation Solution
A lubrication system with two pressure sensors positioned at different points along the supply line, where a controller uses the differential pressure between these sensors to accurately determine when the desired pressure has been achieved at downstream injectors, thereby controlling the pump operation and preventing excessive pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pressure sensor is used to control pump operation, then the system is simpler, but the pressure measurement precision at downstream injectors deteriorates
Solution Approach 1:
The supply line is segmented into multiple sections with pressure sensors positioned at different locations (upstream near the pump and downstream near the injectors). This segmentation allows independent measurement of pressure at critical points, enabling accurate determination of downstream pressure without requiring a single complex sensor system.
Solution Approach 2:
The controller acts as an intermediary that receives pressure signals from multiple sensors and processes them to determine when desired pressure has been achieved at downstream positions. The controller uses the pressure differential between upstream and downstream sensors to accurately control pump operation, eliminating the need for direct pressure measurement at the injector location.
2Measurement precision
If the pressure sensor is placed far downstream near the injectors, then the pressure measurement precision improves, but the ease of operation and reliability deteriorate due to harsh environmental conditions
Solution Approach 1:
Instead of placing a single sensor in the harsh downstream environment, the system segments the measurement function across multiple sensors positioned at different locations. The upstream sensor remains in a protected environment while the downstream sensor (when used) is positioned to measure pressure without being directly exposed to the harshest conditions at the injector points.
Solution Approach 2:
The controller serves as an intermediary that calculates downstream pressure conditions based on upstream pressure measurements and pressure differential data. This eliminates the need to place sensitive sensors directly in the harsh environmental conditions near the injectors, as the controller can determine downstream pressure status using data from more protected sensor locations.
3Device complexity
If a timer-based control system is used, then the device complexity is reduced, but the manufacturing precision of lubrication timing deteriorates
Solution Approach 1:
The system uses feedback from pressure sensors to control pump operation. The controller continuously monitors pressure signals from upstream and downstream sensors, and adjusts pump operation based on the actual pressure conditions. This feedback mechanism ensures precise lubrication timing based on real pressure conditions rather than fixed timer intervals, achieving accurate lubrication delivery regardless of system variations.
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 provides precise control over lubrication, ensuring that critical machine components are properly lubricated, reducing downtime and preventing damage by accurately determining pressure and managing pump pressure within optimal limits.
Implementation Method 1
a first pressure sensor associated with the supply line at a first position, and a second pressure sensor associated with the supply line at a second position downstream of the pump and the first pressure sensor position
Implementation Method 2
The signals from these sensors are processed by a controller configured to control system operation based upon the pressure differential between the positions associated with the sensors
Implementation Method 3
a pump operatively connected to a supply line to deliver a lubricant
Data Source
AI summary
A lubrication system is provided that includes a pump operatively connected to one or more supply lines for delivery of a lubricant, the system including a first pressure sensor associated with the supply line at a first position, and a second pressure sensor associated with the supply line at a second position downstream of the first position and pump, a controller configured to receive pressure signals and control operation of the pump based upon the pressure differential between the pressures at the first position and second position. The pressure differential may be employed to determine when a pressure at a third position downstream of the second position has been achieved. At least one of the pressure sensors may be positioned adjacent to the pump, the controller further being operable to deactivate the pump in the event that a maximum pump pressure has been met.