Lubrication Unit Flow Rate Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated lubrication systems face challenges in accurately dispensing lubricant at extreme cold temperatures, where the lubricant becomes viscous, leading to incomplete filling of the pump cylinder, which results in insufficient lubrication due to reliance on pump cylinder volume and flow rate calculations.
Innovation Solution
A lubrication unit with a motor-driven pump and flow rate sensor that adjusts pump speed based on measured flow rate to achieve a preselected flow rate, allowing for direct control from flow rate measurements and ensuring accurate lubricant delivery, even in viscous conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pump cylinder volume is used to determine lubricant flow rate, then the system is simple to operate, but the measurement becomes inaccurate when lubricant does not fill the cylinder (e.g., in extreme cold temperatures)
Solution Approach 1:
The patent introduces a flow rate sensor that provides feedback on the actual lubricant flow rate. The control system compares the measured flow rate with the desired flow rate and adjusts the pump speed accordingly. This closed-loop feedback mechanism ensures accurate flow rate measurement and control regardless of whether the pump cylinder is completely filled, resolving the measurement accuracy problem while maintaining system simplicity through automated control.
2Productivity
If pump speed is increased to compensate for viscous lubricant in cold temperatures, then more lubricant can be drawn into the cylinder, but the flow rate control becomes inaccurate if the cylinder is not completely filled
Solution Approach 1:
The flow rate sensor provides real-time feedback on the actual lubricant delivery, allowing the control system to distinguish between intentional speed increases for productivity and incomplete cylinder filling. The system uses this feedback to maintain accurate flow rate control even when operating at higher speeds in cold temperatures, ensuring that productivity gains do not compromise measurement precision.
Solution Approach 2:
The patent replaces the mechanical assumption of complete cylinder filling with an electronic flow rate sensor that directly measures actual lubricant delivery. This substitution eliminates the need to rely on mechanical volume calculations and provides accurate flow rate measurement regardless of cylinder fill level or pump speed, resolving the contradiction between productivity and measurement precision.
3Measurement precision
If a flow rate sensor is added to enable direct flow rate control, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The flow rate sensor is integrated into an automated control system that uses feedback to adjust pump speed. This automation reduces the need for manual intervention and complex manual calculation procedures, offsetting the added sensor complexity with simplified operational procedures. The system maintains accuracy while managing complexity through intelligent control algorithms.
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
Enables precise control of lubricant delivery, ensuring consistent and sufficient lubrication to lubrication points, even at low temperatures, by using a flow rate sensor to adjust pump speed and determine the volume delivered.
Implementation Method 1
a flow rate sensor mounted downstream from the pump for measuring a flow rate of lubricant pushed out of the cylinder
Implementation Method 2
a motor, and an axial piston pump in fluid communication with the reservoir and having a piston driven by the motor
Data Source
AI summary
A lubrication unit for delivering lubricant in a system and a method for controlling the unit. The lubrication unit includes a reservoir, a motor, and a pump. The lubrication unit has a flow rate sensor mounted downstream from the pump for measuring a flow rate of lubricant. The lubrication unit includes a control unit operatively connected to the flow rate sensor and the motor for controlling operation of the motor. The control unit includes an input selector for selecting at least one characteristic selected from a group consisting of a volume and a flow rate of lubricant pumped by the pump. The control unit adjusts motor speed to obtain the selected characteristic.