Supplemental Pump Filtration for Low-Loss Machine Lubrication
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Solution Overview
Problem
Existing machinery systems face challenges in effectively filtering smaller particle sizes due to high pressure requirements and space constraints of fine filtration media, leading to excessive parasitic power losses and inadequate lubrication, while coarse filters fail to remove fine particles efficiently, resulting in premature component wear and high maintenance costs.
Innovation Solution
Implementing a supplemental pump and filter system that activates based on filter triggering conditions, such as fluid viscosity and contaminant levels, to provide fine filtration when needed, reducing parasitic power consumption and optimizing fluid flow for efficient lubrication, using a 'kidney loop' arrangement to enhance filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine filtration media is used to filter smaller particles, then filtration efficiency is improved, but parasitic power losses increase and space requirements increase
Solution Approach 1:
The coarse filter is positioned upstream to remove larger particles before the fluid reaches the fine filtration media. This preliminary filtration action reduces the contaminant load on the fine filter, allowing it to operate with lower pressure differential and reduced parasitic power losses while maintaining filtration efficiency for smaller particles
Solution Approach 2:
The filtration system is segmented into two distinct stages: a coarse filter for larger particles and a fine filter for smaller particles. This segmentation allows each filter to be optimized for its specific particle size range, with the coarse filter handling the bulk of contaminant removal and the fine filter focusing on smaller particles with reduced energy penalty
2Manufacturing precision
If fine filtration media is used to filter smaller particles, then filtration efficiency is improved, but device complexity and space requirements increase
Solution Approach 1:
The filtration system is divided into a coarse filter section and a fine filter section, with each segment handling different particle sizes. This segmentation allows the fine filtration media to be more compact since it doesn't need to handle the full contaminant load alone, reducing overall space requirements while maintaining filtration efficiency
Solution Approach 2:
The coarse filter performs preliminary particle removal upstream, reducing the contaminant burden on the fine filter. This allows the fine filtration media to be designed with smaller surface area requirements, reducing device complexity and space requirements while achieving the same filtration efficiency for small particles
3Loss of energy
If coarse filters are used, then parasitic power losses are reduced, but filtration efficiency for smaller particles deteriorates
Solution Approach 1:
The filtration function is segmented between a coarse filter for larger particles and a fine filter for smaller particles. The coarse filter handles the majority of contaminant removal with low energy loss, while the fine filter specifically targets smaller particles that would otherwise pass through, achieving both low parasitic power losses and high filtration efficiency for small particles
Solution Approach 2:
The coarse filter performs preliminary filtration of larger particles before the fluid enters the fine filter section. This preliminary action reduces the contaminant load on the fine filter, allowing it to achieve high filtration efficiency for smaller particles with minimal pressure differential and low parasitic power losses
4Reliability
If inadequate lubrication occurs, then component wear increases, but maintaining proper lubrication requires continuous fluid circulation
Solution Approach 1:
The pump activates before the engine starts to perform preliminary lubrication of critical components. This preliminary action ensures that bearings and other moving parts are adequately lubricated before operation begins, preventing wear without requiring continuous high-volume fluid circulation during idle or low-load conditions
Solution Approach 2:
The pump operates periodically rather than continuously, activating before engine start for pre-lubrication and potentially during shutdown for post-lubrication. This periodic operation reduces energy consumption compared to continuous circulation while maintaining component reliability through targeted lubrication at critical times
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
The system effectively filters smaller particles, reduces parasitic power losses, and optimizes fluid flow, extending equipment life and minimizing maintenance downtime by ensuring adequate lubrication, thereby reducing maintenance costs and improving machinery performance.
Implementation Method 1
supplemental pump and filter system that activates based on filter triggering conditions
Implementation Method 2
fine filtration media require either substantially high pressure across the filter
Implementation Method 3
inadequate lubrication of components prior to engine ignition
Data Source
AI summary
A system for controlling a fluid operation of a machine. The system includes a main pump of the machine, a supplemental pump of the machine, a fluid maintenance circuit comprising a processing circuit, and control system. The fluid maintenance system includes at least one memory device and at least one processor configured to access the memory device. The control system comprises a processing circuit, is electrically couplable to the main pump, the supplemental pump and the fluid maintenance circuit, and is configured to control the post-lubrication operation of the machine based on at least one of the following (1) a fluid operation service schedule and (2) data associated with the machine.