CN112902000A - Fault prediction and processing method of progressive lubricating oil distributor - Google Patents
Fault prediction and processing method of progressive lubricating oil distributor Download PDFInfo
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- CN112902000A CN112902000A CN202110070621.7A CN202110070621A CN112902000A CN 112902000 A CN112902000 A CN 112902000A CN 202110070621 A CN202110070621 A CN 202110070621A CN 112902000 A CN112902000 A CN 112902000A
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- Prior art keywords
- distributor
- blockage
- progressive
- preset
- lubricating oil
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N25/00—Distributing equipment with or without proportioning devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N29/00—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems
- F16N29/04—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems enabling a warning to be given; enabling moving parts to be stopped
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N7/00—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated
- F16N7/38—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated with a separate pump; Central lubrication systems
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N2260/00—Fail safe
Abstract
The application provides a fault prediction and processing method of a progressive lubricating oil distributor, which does not change the mechanical structure and the sensor mode of the original distributor, analyzes the collected data through a specific algorithm, can predict the blockage condition of the distributor and can accurately and quantitatively output grease. Meanwhile, when the distributor is about to or has partial fault, the distributor is preprocessed by an external device, so that the aims of solving the blockage fault of the distributor and prolonging the service life of the distributor are fulfilled. Meanwhile, the invention has simple structure, less parts, easy manufacture, high reliability and low price.
Description
Technical Field
The invention relates to the technical field of distributors of large-scale mechanical lubrication systems, in particular to a fault prediction and processing method of a progressive lubricating oil distributor.
Background
Currently, in lubrication systems for large machines, especially progressive lubrication systems, a plunger dispenser is typically used to dispense lubricant to one or more lubrication points by a metered manner. These dispensers are usually realized in a purely mechanical structure, with a metered amount of lubricant being dispensed as the stroke of each plunger is metered. The plunger is controlled to move in one or the other direction depending on the pressure applied and the amount of lubricant dispensed can be determined by counting the number of strokes or time the plunger is moved. For proper operation, i.e. to determine whether the plunger has performed the intended stroke correctly, dispensers that are common today use a stroke sensor to monitor the movement of the plunger. In addition, in order to extrude the grease to the lubricating points at different distances, high pressure of hundreds of bars exists in the distributor, so the sleeve and the plunger are of a closed structure. This design places very high demands on the tightness of the components and, because of the reciprocating movement of the plunger, wear inevitably occurs which, after a certain period of use, affects the performance of the components, resulting in inaccurate lubricant dispensing. Meanwhile, the lubricant is deposited due to the generation of the abrasion clearance of the parts, and the lubricant is coagulated into blocks for a long time, so that the moving structure of the plunger is blocked.
Therefore, a new method for predicting and handling the failure of the progressive lubricant dispenser is needed.
Disclosure of Invention
In view of the above, the present invention provides a failure prediction method for a progressive lubricant distributor, which is characterized in that: the method is suitable for a progressive lubricating oil dispenser, the method comprising:
s1: acquiring an output signal of a proximity sensor of the progressive lubricating oil dispenser;
s2: collecting the output signals of the proximity sensors in the step S1 according to a preset frequency, counting the times of outputting the rated minimum output value of the proximity sensors in the sampling times in a preset time period, recording the times of the rated minimum output value as T0, meanwhile, counting the times of outputting the rated maximum output value of the proximity sensors in the sampling times in the preset time period, and recording the times of the rated maximum output value as T1;
s3: determining the number of edges according to the sampling number of the step S2, wherein the edges are from T1 to T0, or represent the change from T0 to T1, namely the change from T1 to T0 is recorded as one edge, or the change from T0 to T1 is recorded as one edge;
s4: judging whether the edge number is a preset positive integer or not, if not, classifying the blockage into the highest grade 7, performing blockage alarm, and if so, entering the next step;
s5: the clogging factor delta is determined and,
wherein δ represents a blocking factor, T1 represents the sampling frequency of the maximum output value of the proximity sensor output obtained according to the preset sampling frequency within the preset time period, and T0 represents the sampling frequency of the minimum output value of the proximity sensor output obtained according to the preset sampling frequency within the preset time period;
s6: and comparing the blockage factor delta with a preset blockage grade threshold value to determine the blockage grade of the distributor.
Further, the preset time period is a positive integer multiple of the initialization time of the progressive lubricating oil distributor.
Further, the initialization time includes a time when the output value of the proximity sensor has an edge when the dispenser is first used.
Further, the preset positive integer has the same value as a positive integer multiple of the initialization time in the preset time period.
Further, the threshold value of the congestion level includes:
accordingly, the present invention also provides a failure prediction method of a progressive lubricating oil dispenser, which is applied to the failure prediction method of any one of claims 1 to 4, characterized in that: the method comprises the following steps:
when the clogging is classified as 1 or 2, no treatment is performed;
when the blockage is classified as 3, the heating function of the distributor is started;
when the blockage is graded as 4 or 5, the heating and pressurizing functions of the distributor are started;
when the blockage is classified as 6, sending out a blockage early warning signal;
when the congestion is classified as 7, a congestion warning message is issued.
The invention has the beneficial technical effects that: according to the method and the device, the mechanical structure and the sensor mode of the original distributor are not changed, data are collected through a software algorithm for analysis, the blockage condition of the distributor can be predicted, and the grease can be accurately and quantitatively output. Meanwhile, when the distributor is about to or has partial fault, the distributor is preprocessed by an external device, so that the aims of solving the blockage fault of the distributor and prolonging the service life of the distributor are fulfilled. Meanwhile, the invention has simple structure, less parts, easy manufacture, high reliability and low price.
Drawings
The invention is further described below with reference to the following figures and examples:
fig. 1 is a schematic view of a progressive lubricant distributor.
In fig. 1, 1-a heater upper cover, 2-a heater lower cover, 3-an oil inlet, 4-a fixing screw, 5-a heater driving connector, 6-a proximity sensor and 7-a heating sheet.
Detailed Description
The invention is further described with reference to the accompanying drawings in which:
because the generation of wear gaps in the components of progressive lubricant distributors can cause lubricant to settle and over time cause the lubricant to clump and cause clogging of the plunger moving structure.
The invention provides a fault prediction method of a progressive lubricating oil distributor, which is characterized by comprising the following steps: the method is suitable for a progressive lubricating oil dispenser, the method comprising:
s1: acquiring an output signal of a proximity sensor of the progressive lubricating oil dispenser;
s2: collecting the output signals of the proximity sensors in the step S1 according to a preset frequency, counting the times of outputting the rated minimum output value of the proximity sensors in the sampling times in a preset time period, recording the times of the rated minimum output value as T0, meanwhile, counting the times of outputting the rated maximum output value of the proximity sensors in the sampling times in the preset time period, and recording the times of the rated maximum output value as T1; the proximity sensors of the respective manufacturers output values that differ, and in this embodiment, the output rated minimum value is 0V and the output rated maximum value is + 24V.
S3: determining the number of edges according to the sampling number of the step S2, wherein the edges are from T1 to T0, or represent the change from T0 to T1, namely the change from T1 to T0 is recorded as one edge, or the change from T0 to T1 is recorded as one edge;
the output of the grease is related to the flow characteristics of the grease itself, the structural characteristics of the distributor, the number of outlets of the distributor, the characteristics of the pipeline, the temperature and other factors. Along with the change of time, the whole oil circuit can be changed from an initial unblocked state to a blocked state. If the grease output is controlled according to the original method of controlling the running time of the motor, the grease output is smaller and smaller, which is not consistent with the mechanical structure characteristics of the required lubrication.
The proximity sensor outputs signals of 0V and +24V, corresponding to the position of the plunger inside the dispenser away from and close to the sensor, respectively. The signals are processed by the lubricating pump control board and are respectively marked as T0 and T1, the signals respectively represent the sampling number of 0V and +24V, the change from T0 to T1 or from T1 to T0 is marked as an edge, the control board counts the edges, the counting is started when the motor runs, the motor stops when 3 edges are counted, the edge counting method is positively correlated with the motion track of the plunger inside the distributor, meanwhile, the influence of other factors on the oil output quantity of the distributor can be eliminated, and the oil output quantity of the distributor can be accurately controlled.
S4: judging whether the edge number is a preset positive integer or not, if not, classifying the blockage into the highest grade 7, performing blockage alarm, and if so, entering the next step;
s5: the clogging factor delta is determined and,
wherein δ represents a blocking factor, T1 represents the sampling frequency of the maximum output value of the proximity sensor output obtained according to the preset sampling frequency within the preset time period, and T0 represents the sampling frequency of the minimum output value of the proximity sensor output obtained according to the preset sampling frequency within the preset time period;
the open or blocked condition of the dispenser is correlated to the output value of the proximity sensor. Experiments prove that when the distributor changes from the unblocked state to the blocked state, the delta is gradually increased, so that the blocked state of the distributor can be predicted according to the delta value.
S6: and comparing the blockage factor delta with a preset blockage grade threshold value to determine the blockage grade of the distributor. In this embodiment, the algorithm may be written as a program, and the calculation is performed automatically by directly implementing the algorithm through software.
According to the technical scheme, the blockage condition of the distributor is determined by analyzing the acquired data without changing the mechanical structure and the sensor mode of the original distributor.
The preset time period is a positive integer multiple of the initialization time of the progressive lubricating oil distributor. In this embodiment, the positive integer multiple is selected to be 3, that is, 3 edges are included in the predetermined time period.
The initialization time includes a time when the output value of the proximity sensor has an edge when the dispenser is first used. Correspondingly, the method further comprises an activation step, wherein the activation step is an initialization process and is similar to the activation function of the mobile phone. A user needs to send an 'activation' command to the lubricating pump through remote control software, the lubricating pump can automatically drive the motor to fill grease after receiving the command, the initialization process is ended until the proximity sensor has a complete period of output signals, and parameters such as a blocking factor can be calculated only through activated equipment.
The preset positive integer is the same as a positive integer multiple of the initialization time in the preset time period.
The threshold values for the congestion level include:
the person skilled in the art can determine the jam level according to the accuracy of grading the jam and the actual need, and in this embodiment, the jam level is as shown in equation 2, the jam factor is calculated by equation 1, and then the jam factor is compared with equation 2 to determine the jam level.
Accordingly, the present invention also provides a failure prediction method of a progressive lubricating oil dispenser, which is applied to the failure prediction method of any one of claims 1 to 4, characterized in that: the method comprises the following steps:
when the clogging is classified as 1 or 2, no treatment is performed;
when the blockage is classified as 3, the heating function of the distributor is started;
when the blockage is graded as 4 or 5, the heating and pressurizing functions of the distributor are started;
when the blockage is classified as 6, sending out a blockage early warning signal;
when the congestion is classified as 7, a congestion warning message is issued.
As shown in fig. 1, the dispenser is mainly composed of a heater upper cover, a heater lower cover, an oil inlet, a fixing screw, a heater driving connector, a proximity sensor, and a heating sheet. The pressure inside the distributor is controlled by the output pressure of the lubricating pump, the approach sensor and the pressure relief valve together.
Heating: the lubricating pump control panel drives the heating module to work, the working time is 30 minutes, and the temperature rise is 35 ℃.
Pressurizing: the lubricating pump control panel drives the motor to work, and the working time is 30 seconds.
Finally, the above embodiments are only for illustrating the technical solutions of the present invention and not for limiting, although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions may be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all of them should be covered in the claims of the present invention.
Claims (6)
1. A failure prediction method for a progressive lubricating oil distributor is characterized in that: the method is suitable for a progressive lubricating oil dispenser, the method comprising:
s1: acquiring an output signal of a proximity sensor of the progressive lubricating oil dispenser;
s2: collecting the output signals of the proximity sensors in the step S1 according to a preset frequency, counting the times of outputting the rated minimum output value of the proximity sensors in the sampling times in a preset time period, recording the times of the rated minimum output value as T0, meanwhile, counting the times of outputting the rated maximum output value of the proximity sensors in the sampling times in the preset time period, and recording the times of the rated maximum output value as T1;
s3: determining the number of edges according to the sampling number of the step S2, wherein the edges are from T1 to T0, or represent the change from T0 to T1, namely the change from T1 to T0 is recorded as one edge, or the change from T0 to T1 is recorded as one edge;
s4: judging whether the edge number is a preset positive integer or not, if not, classifying the blockage into the highest grade 7, performing blockage alarm, and if so, entering the next step;
s5: the clogging factor delta is determined and,
wherein δ represents a blocking factor, T1 represents the sampling frequency of the maximum output value of the proximity sensor output obtained according to the preset sampling frequency within the preset time period, and T0 represents the sampling frequency of the minimum output value of the proximity sensor output obtained according to the preset sampling frequency within the preset time period;
s6: and comparing the blockage factor delta with a preset blockage grade threshold value to determine the blockage grade of the distributor.
2. The method of fault prediction for a progressive lubricant dispenser of claim 1, further comprising: the preset time period is a positive integer multiple of the initialization time of the progressive lubricating oil distributor.
3. The method of fault prediction for a progressive lubricant dispenser of claim 2, wherein: the initialization time includes a time when the output value of the proximity sensor has an edge when the dispenser is first used.
4. The method of fault prediction for a progressive lubricant dispenser of claim 1, further comprising: the preset positive integer is the same as a positive integer multiple of the initialization time in the preset time period.
5. The method of fault prediction for a progressive lubricant dispenser of claim 1, further comprising: the threshold values for the congestion level include:
6. a failure prediction method of a progressive lubricating oil dispenser, the method being applied to the failure prediction method of any one of claims 1 to 4, characterized in that: the method comprises the following steps:
when the clogging is classified as 1 or 2, no treatment is performed;
when the blockage is classified as 3, the heating function of the distributor is started;
when the blockage is graded as 4 or 5, the heating and pressurizing functions of the distributor are started;
when the blockage is classified as 6, sending out a blockage early warning signal;
when the congestion is classified as 7, a congestion warning message is issued.
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| CN202110070621.7A CN112902000B (en) | 2021-01-19 | 2021-01-19 | Fault prediction and processing method of progressive lubricating oil distributor |
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| CN202110070621.7A CN112902000B (en) | 2021-01-19 | 2021-01-19 | Fault prediction and processing method of progressive lubricating oil distributor |
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Citations (3)
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|---|---|---|---|---|
| JP2015183847A (en) * | 2014-03-26 | 2015-10-22 | 本田技研工業株式会社 | Lubricant supply confirmation device and lubricant supply confirmation method |
| CN207749338U (en) * | 2017-06-23 | 2018-08-21 | 无锡小天鹅股份有限公司 | Device for clothing processing |
| CN212179140U (en) * | 2020-03-27 | 2020-12-18 | 上海兆泰电动科技有限公司 | Air interchanger capable of detecting blocking state of filter screen |
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- 2021-01-19 CN CN202110070621.7A patent/CN112902000B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2015183847A (en) * | 2014-03-26 | 2015-10-22 | 本田技研工業株式会社 | Lubricant supply confirmation device and lubricant supply confirmation method |
| CN207749338U (en) * | 2017-06-23 | 2018-08-21 | 无锡小天鹅股份有限公司 | Device for clothing processing |
| CN212179140U (en) * | 2020-03-27 | 2020-12-18 | 上海兆泰电动科技有限公司 | Air interchanger capable of detecting blocking state of filter screen |
Non-Patent Citations (3)
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| 康涛: "基于可靠性的递进式润滑系统堵塞故障原因分析及方案探讨", 《第六届中国风电后市场交流合作大会论文集》 * |
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