Automatic Lubricator Piston Sensing for Level and Blockage Monitoring
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Solution Overview
Problem
Automatic lubricators lack efficient and reliable methods to determine lubrication parameters such as lubricant levels and blockages, leading to potential equipment failure and increased maintenance costs.
Innovation Solution
An automated lubricator with a sensor system that measures the distance between the sensor and the piston within the lubricant container, allowing for accurate determination of lubrication parameters, independent of container type or size, and enabling real-time monitoring of lubricant levels and blockages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual application of lubricant is used, then maintenance effort and costs are high, but automation is not achieved
Solution Approach 1:
The lubricator is configured to automatically determine lubrication parameters such as lubricant levels and blockages without requiring manual intervention. The sensor system and control circuitry enable the device to self-monitor and self-adjust, eliminating the need for manual checking and maintenance while reducing operational effort.
2Adaptability or versatility
If traditional sensor arrangement is used (sensor connected to container), then sensor replacement is required with container, but this increases costs and complexity
Solution Approach 1:
The sensor system is segmented from the lubricant container, with the sensor arranged in the housing rather than being integrated into the container. This allows the sensor to remain with the lubricator housing while the container can be independently replaced, simplifying maintenance and reducing costs.
Solution Approach 2:
The sensor arrangement in the housing makes it universally compatible with different container types and sizes. The sensor measures distance to the piston through the container walls, allowing the same sensor system to work with various container configurations without requiring sensor replacement.
3Reliability
If lubrication parameters are not accurately determined, then equipment failure risk increases, but with proper monitoring equipment costs increase
Solution Approach 1:
The patent replaces complex mechanical monitoring systems with a sensor-based measurement system. The sensor uses electromagnetic or optical fields to measure the distance to the piston, eliminating the need for complex mechanical linkages while providing accurate real-time monitoring of lubrication parameters.
Solution Approach 2:
The control circuitry receives sensor signals and uses this feedback to determine lubrication parameters such as lubricant levels and blockages. This feedback mechanism enables automatic detection of abnormal conditions and triggers appropriate responses, improving reliability without requiring complex external monitoring systems.
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 reliable, efficient, and cost-effective monitoring of lubrication parameters, reducing maintenance efforts and ensuring proper lubrication, while being independent of environmental conditions like vibration and temperature.
Implementation Method 1
at least one sensor arranged within the housing and configured to provide a sensor signal indicative, representative and/or descriptive of a distance between the at least one sensor and the piston of the lubricant container
Data Source
AI summary
An automatic lubricator for lubricating an object. The lubricator includes a housing with a coupling section configured to couple with a lubricant container containing a lubricant. The lubricant container includes a rotatable shaft with a piston to dispense the lubricant from an output of the lubricant container. An electric motor is 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. At least one sensor is arranged within the housing and configured to provide a sensor signal indicative of a distance between the at least one sensor and the piston of the lubricant container, and a control circuitry configured to determine, based on the sensor signal, at least one lubrication parameter indicative of the at least one lubrication action.