Progressive Lubrication Pressure Monitoring for Blockage Detection
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Solution Overview
Problem
Existing lubrication systems with progressive distributors struggle to detect partial blockages, impending blockages, and line breaks, as current detection methods only identify complete blockages or failures, and require multiple sensors placed throughout the system.
Innovation Solution
Incorporating a pressure sensor upstream of the metering pistons in the lubrication system, which communicates with a control device to detect lubrication cycles, determine average pressure, and compare it to normal pressure values, allowing for comprehensive monitoring with fewer sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sensors are placed throughout the lubrication system to detect partial blockages, line breaks, and pressure changes, then the detection capability and reliability are improved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple detection functions (pressure monitoring, flow monitoring, blockage detection, line break detection) into a single pressure sensor positioned upstream of the progressive distributor. This single sensor captures pressure variations that indicate all types of malfunctions, eliminating the need for multiple separate sensors throughout the system while maintaining comprehensive monitoring capability
Solution Approach 2:
The pressure sensor is designed to perform multiple detection functions simultaneously: detecting partial blockages, complete blockages, line breaks, and pump failures. By positioning the sensor upstream of the progressive distributor, it can monitor pressure changes that reflect the state of the entire lubrication system, making it a universal monitoring solution
2Device complexity
If a single pressure sensor is used upstream of the progressive distributor, then the device complexity and cost are reduced, but the ability to detect all types of malfunctions (partial blockages, line breaks, etc.) is compromised
Solution Approach 1:
The control device continuously monitors pressure signals from the upstream pressure sensor and uses feedback algorithms to detect malfunctions. The system compares pressure variations against expected patterns to identify partial blockages, complete blockages, line breaks, and pump failures, enabling reliable detection with minimal hardware
Solution Approach 2:
The patent replaces the traditional mechanical approach of using multiple physical sensors distributed throughout the system with a single pressure sensor combined with electronic signal processing and control algorithms. The control device analyzes pressure patterns to infer system state, substituting computational analysis for physical sensor distribution
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 detection of faults such as blockages, kinks, and line breaks, while being more cost-effective than traditional multi-sensor systems, and allows for continuous learning and adaptation of normal pressure values.
Implementation Method 1
The progressive distributor can include at least one sensor (8) that is configured to determine at least one lubricant pressure inside the lubrication system (1)
Implementation Method 2
the metering piston is displaceable in the piston bore and is configured to alternatively release the one or the other lubricant outlet bore
Implementation Method 3
the piston bores are mutually fluidically connected to one another via connecting bores in order to transfer lubricant to the other piston bores
Data Source
AI summary
A lubrication system includes a progressive distributor that is configured to dispense lubricant to a consumer. The lubrication system also includes a control device and at least one sensor that is configured to determine at least one lubricant pressure inside the lubrication system. The control device is configured to receive measured values from the at least one sensor and to recognize a lubrication cycle based on the measured values and also to determine an average pressure of the lubrication cycle, to perform a comparison of the average pressure and at least one normal pressure of the lubrication system, and to determine a state of the lubrication system based on a result of the comparison.