Automatic Lubricator Current-Signal Monitoring for Sensorless Dosing
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Solution Overview
Problem
Existing automatic lubricators lack efficient and reliable methods to determine lubrication parameters, such as lubrication frequency and amount, without requiring additional sensors, leading to potential malfunctions and increased maintenance costs.
Innovation Solution
An automatic lubricator with a control circuitry that analyzes the periodicity of the supply current signal to determine lubrication parameters, including lubrication frequency and blockages, using techniques like Fourier transforms and autocorrelation functions, without the need for dedicated sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors are used to determine lubrication parameters, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The lubricator uses its existing power supply system to generate measurement signals for determining lubrication parameters. The control circuitry analyzes the periodicity of the supply current signal to extract lubrication information without requiring external sensors, making the system self-sufficient for measurement purposes
Solution Approach 2:
The supply current signal serves dual purposes: powering the electric motor and providing measurement data for lubrication parameter determination. The same electrical infrastructure is used both for actuation and for sensing, eliminating the need for separate measurement components
2Productivity
If manual lubrication application is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The control circuitry continuously monitors the supply current signal periodicity and uses this feedback to automatically adjust and optimize lubrication parameters. The system self-regulates based on real-time electrical signal analysis, enabling automated lubrication without manual intervention
Solution Approach 2:
Manual mechanical lubrication monitoring and adjustment is replaced by automated electrical signal analysis. The control circuitry processes the electrical supply current to determine lubrication parameters, substituting manual mechanical operations with automated electronic control
3Reliability
If lubrication parameters are not accurately determined, then device complexity is reduced, but reliability decreases
Solution Approach 1:
The supply current signal acts as an intermediary carrier that contains information about lubrication parameters. By analyzing the periodicity of this electrical signal, the system indirectly determines lubrication status without direct mechanical contact or additional sensing components
Data Source
AI summary
An automatic lubricator for lubricating an object is described, which comprises a housing with a coupling section configured to couple with a lubricant container containing a lubricant, wherein the lubricant container comprises a rotatable shaft with a piston to dispense the lubricant from an output of the lubricant container. The lubricator further comprises an electric motor configured to drive the rotatable shaft of the lubricant container during at least one lubrication action, such that at least a part of the lubricant is dispensable from the lubricant container during the at least one lubrication action, and a power supply configured to supply the electric motor with a supply current during the at least one lubrication action. The lubricator further comprises a control circuitry configured to acquire a current signal indicative of the supply current over time during at least a part of the at least one lubrication action, determine a periodicity of the acquired current signal, and determine, based on the determined periodicity, at least one lubrication parameter indicative of the at least one lubrication action.