Semisolid Lubricant Distribution System with Controlled Suction
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Solution Overview
Problem
Lubrication systems with semisolid lubricants, particularly those using volumetric injectors or double line systems, face issues with saponification leading to pipe blockages and prolonged depressurization cycles, resulting in extended idle times and inefficient filling processes due to non-homogeneous depressurization and prolonged high-pressure exposure.
Innovation Solution
A controlled suction/delivery device is integrated into the lubrication system, utilizing an accumulation cylinder and pneumatic piston to actively manage pressure by suctioning lubricant during inactivity and reintroducing it during activity, aided by pressure sensors and control units to optimize pressurization and depressurization cycles, reducing cycle times and minimizing saponification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the system uses long pipes for distribution, then the coverage area is increased, but the depressurization becomes non-homogeneous and cycle time increases
Solution Approach 1:
The system divides the distribution network into multiple zones with separate control. Each zone has its own control valve that can be independently operated, allowing selective depressurization of specific segments rather than the entire system. This enables faster localized depressurization while maintaining system-wide coverage.
Solution Approach 2:
The system employs dynamic control of distribution valves based on real-time pressure sensor feedback. During depressurization phases, valves are dynamically adjusted to prioritize pressure release in specific zones, enabling non-uniform pressure distribution that accelerates overall cycle time while accommodating long pipe networks.
2Reliability
If the grease density is high, then the lubrication effectiveness is improved, but the depressurization speed decreases due to grease acting as a cap
Solution Approach 1:
The system performs preliminary depressurization actions at the beginning of each cycle by opening distribution valves before the main depressurization phase. This preliminary action creates pressure pathways that prevent grease from forming caps, enabling faster subsequent depressurization while maintaining the benefits of high-density grease during the lubrication phase.
Solution Approach 2:
The distribution valves act as intermediaries that control grease flow and pressure distribution. By strategically opening and closing these valves, the system mediates between the need for high grease density (for effective lubrication) and the need for rapid depressurization, creating controlled flow paths that prevent cap formation.
3Reliability
If the pressurization duration is extended, then the lubricant distribution is improved, but the saponification risk increases
Solution Approach 1:
The system uses periodic pressurization and depressurization cycles with optimized timing. By alternating between pressurization (for distribution) and depressurization (to reduce saponification risk), the system achieves effective lubricant distribution while limiting the cumulative time grease spends under high pressure, thereby reducing saponification.
Solution Approach 2:
The system maintains continuous operation by overlapping pressurization and depressurization phases across different zones. While one zone is being pressurized, another is depressurizing, ensuring that the overall system remains productive without extending the total cycle time, thus limiting saponification exposure.
4Quantity of substance
If the system fills large volumes, then the lubrication capacity is increased, but the filling time extends over days
Solution Approach 1:
The system divides the large-volume filling operation into multiple zones that can be filled simultaneously or in rapid sequence. Each zone has independent control, allowing parallel filling operations that dramatically reduce total filling time while achieving the same overall lubrication capacity.
Solution Approach 2:
The system dynamically adjusts pressure parameters during filling operations. By varying pressure levels and rates across different zones and time periods, the system optimizes filling speed while preventing saponification, enabling rapid filling of large volumes without compromising lubricant quality.
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 significantly reduces cycle times, minimizing saponification risks and cutting filling times by half, allowing for more efficient operation and faster system repressurization, thus enhancing the overall performance and efficiency of the lubrication system.
Implementation Method 1
suction from said first duct a volume of semisolid lubricant during a step of inactivity of the pumping system on said first duct
Implementation Method 2
utilizing an accumulation cylinder and pneumatic piston to actively manage pressure by suctioning lubricant during inactivity and reintroducing it during activity
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A system (1A, 1B) for distributing semisolid lubricant, comprising a semisolid lubricant tank (S) and a high pressure pumping system (2) that intermittently feeds, during a lubrication cycle, at least one first duct (3, 3A), the at least one first duct feeding a plurality of distributors (4, 4A) adapted to sort the semisolid lubricant to a plurality of users (U); it is present, fluidly associated with said first duct (3, 3A), a controlled suction/delivery device (5) of a part of the semisolid lubricant conveyed by said first duct, the controlled suction/delivery device (5) being configured to suck a volume of semisolid lubricant from said first duct during a step of inactivity of the pumping system (2) on said first duct (3, 3A), and to introduce the previously suctioned semisolid lubricant in said first duct during a step of activity of the pumping system (2) on said first duct (3, 3A).