IT202000003730A1 - Control system and related method for machines and / or mechanical devices equipped in particular with mechanical components and / or systems and / or electrical components and / or systems that are lubricated with any type of grease - Google Patents

Description

Description of the industrial invention entitled: Control system and relative method for machines and / or mechanical devices equipped in particular with mechanical components and / or systems and / or electrical components and / or systems that are lubricated by any type of grease ?

Description text

1. SCOPE OF THE TECHNIQUE:

The present invention relates to the field of machines and / or mechanical devices for industrial use equipped in particular with mechanical components and / or systems and / or electrical components and / or systems which are lubricated by any type of grease.

In particular, the following sectors are of interest for the present invention:

? both on-shore and off-shore oil drilling;

? of the processing and refining of liquid and gaseous hydrocarbons including units? Floating Production Storage and Offloading Unit, abbr. in FPSO) or ships or units? floats used for offshore oil production and storage;

? construction relating to the oil segment (jacket, platforms and development of submarine fields etc.) both off-shore and onshore <;>

? of transport always related to the oil segment (pipelines, pumping or compression stations, transport terminals, etc.) both off-shore and onshore <;>

? naval and shipbuilding;

? energy production including wind power;

? hydraulic machines having an internal hydraulic circuit;

? hydraulic lifting machines;

? ground moving machines;

? of industrial vehicles;

? cogeneration relating to the biomass and biogas sectors;

? of other related sectors.

Among the most important machines are those operating on on shore and off shore drilling rigs. In such plants? known the use of numerous types of machines, suitable for the most? various purposes, such as: Drilling Winches (Drawworks), Mud Pumps, Unit? for upper and vertical control of perforation (Top Drive System), Rotary Tables (Rotary Tables), Fixed Sizes (Crown Blocks), Mobile Sizes (Traveling Blocks); and parts of machines such as: Diesel Engines, Alternators, Direct Current Motors, Alternate Current Motors, Mud Agitators, Opossum Belli Systems (Trip Tank System), Centrifugal pumps of all types and sizes (Every type and size of Centrifugal Pumps), Piston pumps of all types and sizes (Every type and size of Piston pumps), Air Compressors, etc.

2. STATE OF THE TECHNIQUE:

To date, machines and / or mechanical devices for industrial use equipped in particular with mechanical components and / or systems and / or electrical components and / or systems that are lubricated with any type of grease, do not have any type of relative automatic control. the level of contamination of the grease by external agents, after the latter (the grease) has performed its lubricating function.

For this reason, the mechanics and maintenance workers of these machines, in order to try to keep the wear of the mechanical components lubricated by grease under control, still continue to practice the empirical and approximate manual technique of palpation of the residues of fat itself, looking for to detect the size and quantity? of metallic particles contained in it.

It is evident that, for the coarseness? of the manual technique described above will result? it is quite difficult to carry out an accurate assessment of the conditions of use of the machine.

3. SOLUTION:

The control system and related method for machines and / or mechanical devices equipped in particular with mechanical components and / or systems and / or electrical components and / or systems that are lubricated by any type of grease, subject of this application for filing of patent, allows, through continuous real-time control of the number and size of both ferrous (magnetic) and non-ferrous (non-ferrous) metal particles contained in the grease leaving the lubrication system by means of a special sensor for detecting metal particles, an accurate evaluation always continues in real time of the conditions of use of the machine.

The control system and related method for machines and / or mechanical devices equipped in particular with mechanical components and / or systems and / or electrical components and / or systems that are lubricated by any type of grease, subject of this application for filing of patent? also equipped with special sensors for real-time control of the instantaneous power and average power absorbed from time to time by the machine to be controlled which will be of fundamental importance for reasons that will be described in the following pages.

This multi-control system can? be considered as a new and innovative advanced diagnosis tool for grease lubricated systems and machines capable of providing specific capabilities? of predictive and preventive maintenance, capable of extending the life of the equipment and guaranteeing the prevention of failures.

Among the numerous and important advantages that the system offers, the following can be mentioned:

? optimizes the overall maintenance of the component with relative significant reduction in costs and operating and maintenance times;

? detects and reports early stage malfunctions before they become breakages and cause extensive damage and long stops for repairs;

? detects and reports lubricant contamination as soon as it occurs;

? it allows to monitor through the control of the parameters the state of use and the conditions of the machines, and the occurrence of alarms, even from mobile devices wherever they are (real-time, cloud-based monitoring);

? detects and reports any lubrication problems in the bud before they become problems for the machines;

? the continuous real-time monitoring of the absorbed power makes it possible to evaluate the exploitation of the controlled machines at any time and for chosen time intervals; for example can? be very useful the evaluation of the power used in the arc of one or more? years;

? it can also be used and applied in hazardous areas (zone 1 IIB) thanks to its Explosion Proof model, necessary for the presence of dangerous explosive gases on construction sites; ? has a self-diagnostic system capable of informing operators and maintenance personnel about the causes, effects and corrective actions to be taken in the event of an internal fault;

? it allows the positioning of the entire control and regulation apparatus, completely outside the machines to be controlled, so that it is totally independent; ? simple to install, without any invasiveness, which makes the solution very suitable for retrofitting and installation on existing machines. In fact, the system does not require any modification of the machine to be controlled;

? ? very versatile, being applicable to grease lubricated systems such as large crown-pinion systems, coupled lever systems, pulleys, bushings, gearboxes, and many more, and provides the highest degree of replicability. of the solution;

? improves personnel safety and environmental protection by minimizing the risk of accidents, a very important goal that can be achieved through the prevention of breakdowns.

4. PURPOSES OF THE INVENTION:

One of the main purposes of this present invention consists in the perfect application of predictive, preventive and programmed maintenance.

To better clarify, we intend to explain in simple form the concepts of predictive and preventive maintenance that can be obtained only and exclusively through the use of the device object of the present invention.

4.1 Concept of predictive maintenance applicable with the device object of the present invention

It appears to be a fact that mechanical parts such as bearings, gears, shafts, etc., are surface treated with hardening processes such as quenching, carburizing and other similar processes.

These mechanical organs mentioned above, as long as? will turn out to be perfectly lubricated with the right quantities? of lubricating fluids and until? they will continue to work on the surfaces treated by the hardening processes, they will produce a low number of ferrous (magnetic) and non-ferrous (non-magnetic) particles which will also have small dimensions.

These numbers and dimensions will depend on the type of machine and the type of use and will remain stable at low values as long as? these mechanical parts will continue to work on the hardened surfaces.

As an example, they will certainly be more? small in the circuits of braking organs, where maximum dimensions of 250? m are foreseen in case of maximum wear, will be a little more? large in the hydraulic circuits of steering systems and in the cooling circuits, where maximum dimensions of 400? m are required in case of maximum wear, a little more? still large in the lubricating circuits for transmission parts, where maximum dimensions of 500? m are required in case of maximum wear and a little more? large anchor in the lubricating circuits of large engines where maximum dimensions of 600? m are required in case of maximum wear.

The values mentioned above are empirical values taken from tables drawn up by the German multinational company HYDAC, one of the leading experts in the sector of oil cleaning and lubrication in general.

With the increase in the working hours of the machines, when the hard surfaces of the mechanical parts begin to wear out, the size and number of particles will slowly begin to increase until reaching the maximum wear dimensions shown in the examples cited above. At that point, the possibilities? of having catastrophic breakdowns will become very big.

Simplifying the concepts, with the device object of the present invention,? It is possible to keep under strict control the size and number of metal particles, therefore, when the size of the particles begins to grow slowly but gradually, it will be? The time has come to carry out the extraordinary cyclical maintenance on the machine.

Andr? from s? that, as long as both outputs are regular, you can? be reasonably certain that the controlled machines will have perfect continuous and regular operation.

4.2 Concept of preventive maintenance applicable with the device object of the present invention

Having clear the concept of predictive maintenance set out above and having clear the concept that even a malfunction or breakdown in the controlled machine would produce an increase in size and number of particles, if the device object of the present invention detects a sudden increase in both number and particle size, it would be a clear symptom of an ongoing malfunction or breakdown in the machine which would be immediately detected thus preventing it? causing serious damage to the machine itself.

Another object of the present invention? describe an even more? innovative and complete control system for grease lubricated machines and a relative innovative method of actuation.

A further object of the present invention? to describe a control system that is easily adaptable to any type of machine already? installed on the system.

Another object of the present invention? to reduce machine downtime and breakdowns before scheduled maintenance takes place, also increasing the life of the machine and reducing wear.

Again, an object of the present invention? to describe a system that allows you to make more? the grease lubricated machines installed (or to be installed) are performing and productive.

Still a further object of the present invention? to propose a system for the control of grease lubricated machines that is economical.

Another object of the invention? to provide a system of control of the operation? and maintenance that is easy to manage and / or automated.

A further object of the present invention? that of providing a stand-alone control system that can be purchased separately from the machine and can be used for one or a plurality of? of different machines, therefore a system that works and can be produced independently of the machine (s) installed.

Still a purpose? that of being able to provide a system of control of the operation? and maintenance in real time even remotely.

A purpose ? moreover, that of creating a system that can be modular and that, that is, can be configured in a unit? or in a plurality? of unit? interconnected with each other.

A further object of the present invention? to provide a system that can allow preventive and predictive maintenance.

An additional purpose? to guide the intervention of specialized personnel in some checks on the functionality? of the plant reducing human errors.

Still a purpose? to reduce the work of maintenance workers.

Still a purpose? optimize scheduled maintenance.

Still a purpose? to reduce the environmental impact of these machines.

An additional purpose? to provide a system for controlling the operation? and maintenance that is accurate and reliable.

Finally, a relevant purpose of the present invention? increase the safety of users on the system and on the system itself.

5. DESCRIPTION OF THE INVENTION:

5.1 REALIZATION OF THE SYSTEM FOR THE ANALYSIS OF THE METALLIC PARTICLES CONTAINED IN THE USED GREASE

In order to analyze both ferromagnetic and non-ferromagnetic metal particles contained in the grease it already has? exercised its lubrication function, it is necessary to collect the used grease which is pushed out through the introduction of the new grease inside the gears which takes place through the use of a special pump that will be pushed out. periodically operated with a frequency established by the manufacturer of the gears to be lubricated.

An example of a system for collecting the used grease and checking the metal particles it contains is shown in drawings 1, 2, 3 and 4.

A truncated cone (2) (or any other regular geometric shape) pi? or less large and more? or less high depending on the size of the gears to be lubricated (1), is it positioned in proximity? of the gears in the area below, so that the used grease, expelled from the new grease, falls by gravity? inside the truncated cone. The truncated cone will come? externally heated by magnetic induction heaters and / or by electrical resistances and / or by air heaters and / or by any other method of heating to an equivalent drop point temperature? of the grease used, to prevent the grease from sticking to the walls without completely entering the truncated cone. The pi? low and more? close of the truncated cone will come? put in communication with a parallelepiped-shaped tray (3), also of variable dimensions depending on the size of the gears, which will contain? all the fat fell into it. This tray will come? it also always heated by magnetic induction heaters and / or by electric resistances and / or by air heaters and / or by any other heating method, at the temperature equivalent to the drop point? of the grease used. At the top of the tray will come? installed a level sensor (4). When will this level sensor come? activated, will come? activated the pump (5) that will provide? to pass the liquefied grease inside the particle sensor (6) positioned on the delivery line of the pump (also kept at the temperature of the dropping point to prevent the grease from solidifying again) to count and measure the metal particles both ferromagnetic than non-ferromagnetic contained in liquefied fat. The pump delivery will go? to bring the liquefied fat into a collecting channel inside which it will solidify? again. The management and automation of the whole system, including the control of the heating temperatures, will come? performed by at least one? unit? programming / microcontroller, such as a PLC or a programmable input-output card, and / or any other type that will come? installed internally in the control box (7), and by at least one control panel, such as a display, an HMI panel, a monitor and / or any other type of communicative screen that will come? installed externally on the control box (7).

? The dropping point defines the temperature at which the fat melts into a liquid with viscosity. dependent on the type of oil used to create the fat itself.

5.2 VARIANTS OF REALIZATION OF THE SYSTEM FOR THE ANALYSIS OF THE METALLIC PARTICLES CONTAINED IN THE GREASE USED:

It should be noted that the embodiment used in the previous paragraph 5.1 represents only an example of a particularly preferred embodiment and does not in any way limit the scope of protection of the present invention.

to. Another example of a preferred embodiment of the innovative system for the control of the lubricating grease can? be the hand collection of the grease in use by an operator or a maintenance technician and then put it in a special container to be heated to the drop point and, using a pump, pass it through the metal particle sensor.

b. Another example of a preferred embodiment of the innovative system for the control of the lubricating grease can? be the use of a grease pump that does not heat the grease to the drop point. c. Another example of a preferred embodiment of the innovative multi-control system can be be, for example, the creation of an explosion-proof model.

In particular, the creation of an explosion-proof model represents a very important and indispensable solution for using the multi-control system in difficult environments such as those relating to the drilling, production and refining sectors. the presence of dangerous explosive gases such as methane.

d. A further example of preferred embodiment may be be for example the possibility? to interconnect an arbitrary number of systems described in the previous paragraphs with each other, varying in number of sensors included in the system, able to exchange and interpret the data collected and also able to simultaneously transmit all the data collected and processed in streaming and / or in special archiving databases. Possible examples of interconnection, which in no way represent the whole? of the possible solutions that can be adopted by the innovative multi-control system and consequently do not in any way limit the protection of this patent application to the following, can be:

? A connection via Profinet network, or any other type, of the microcontrollers of one or more? unit? of the multi-control system, each equipped with an independent electrical part.

? A single centralized microcontroller responsible for managing inputs from multiple sensors belonging to pi? systems each related to a different area of the gears.

6. AVAILABLE SENSORS

6.1 FERROMAGNETIC AND NON-FERROMAGNETIC METALLIC PARTICLES:

How already? analyzed in the paragraphs? Concept of predictive maintenance? e Concept of preventive maintenance? on pages 4 and 5, the real-time detection of the size, number, concentration of the metal particles and the total mass of both ferromagnetic and non-ferromagnetic metal particles, will allow? to realize a real and effective predictive and preventive maintenance.

The trend of these parameters generally remains almost? plate during the period of good operation. Upon the appearance of an anomaly / rupture, the concentration and consequently also the cumulative mass, will increase significantly in a more? or less sudden depending on the entity? of the anomaly / rupture.

There is also a strong correlation between the power absorbed by the controlled machine and its wear, so much so that generally the wear of a machine increases proportionally with the increase in power, up to exponentially increase from 90 to 100% of the power.

It is therefore very useful to evaluate the power in real time to avoid false alarms or, even worse, to prevent possible faults from being not reported. The joint effects of measuring power consumption and metal particles will be examined by the microcontroller during step 6.

The processing of the data detected by the metal particle sensor will be? in turn divided into pi? phases that will be repeated specularly for both ferromagnetic particles and non-ferromagnetic and baser particles? his analysis on different time frames of reference.

The default setting will foresee? three time frames of 10 minutes, 1 hour and 24 hours. The amplitude and number of measurement time intervals can be modified according to the type of machine to be controlled, the type of fluid and the level of safety required by the customer.

? The first phase will consist? in the calculation of the increases, relating to the various dimensional bands, of the number of ferromagnetic and non-ferromagnetic particles over the various pre-established time frames.

? The second phase will consist? in the calculation of the total masses of ferromagnetic and non-ferromagnetic particles measured from the moment of the last reset of the counters and of the increases of the same over the different pre-established time frames. The calculation of the masses will be? carried out on the basis of the values reported by the various meters for the various dimensional bands.

? The third phase will consist? in the calculation of the concentrations of ferromagnetic and non-ferromagnetic particles in the fluid under examination (expressed in the unit of measurement most suited to the type of machine to be controlled,? g / liter and / or mg / liter and / or g / liter) calculated on different pre-established time frames.

The calculation in question will consist? in the divisions of the masses calculated over each specific time span for the total fluid flow calculated over the same time span under examination.

? The fourth and final phase will consist? in the statistical analysis of the data collected and will be? composed of the calculation of a moving average and a standard deviation of the values of the various meters, masses and concentrations. This statistical calculation will render? necessary as the trend of the parameters in question will vary? over time as a result of wear and / or breakage.

? On the basis of the results deriving from the elaboration of the aforementioned steps, the following conditions could be verified, applicable both for ferromagnetic metal particles and for non-ferromagnetic metal particles. In summary, in the list below, only ferromagnetic metal particles will be taken into consideration without in any way limiting their validity. of application for non-ferromagnetic metal particles which will be subjected to exactly the same conditions.

to. If the increases in the numbers of ferromagnetic metal particles referring to specific dimensional bands on the basis of the time span X exceed the reference values for the medium level alarm, the medium level alarm? High increase in the number of ferromagnetic metal particles in the fluid in the time frame X? sar? stored by the microcontroller in the list of alarms. The entity of the increments and the reference dimensional ranges to be set as the alarm threshold will be determined according to the type of machine and the degree of safety required by the customer.

b. If the increases in the numbers of ferromagnetic metal particles referred to specific dimensional bands on the basis of the time span X exceed the reference values for the high-level alarm, the high-level alarm? Critical increase in the number of ferromagnetic metal particles in the fluid in the time frame X? sar? stored by the microcontroller in the list of alarms. The entity of the increments and the reference dimensional ranges to be set as the alarm threshold will be determined according to the type of machine and the degree of safety required by the customer.

c. If the counts of the numbers of ferromagnetic metal particles referred to specific dimensional bands exceed the reference values for the medium level alarm, the medium level alarm? High number of ferromagnetic metal particles in the fluid? sar? stored by the microcontroller in the list of alarms. The entity the reference numbers and dimensional ranges will be determined based on the type of machine and the degree of safety required by the customer.

d. If the counts of the numbers of ferromagnetic metal particles referring to specific dimensional bands exceed the reference values for the high level alarm, the high level alarm? Number of ferromagnetic metal particles in the fluid critically high? sar? stored by the microcontroller in the list of alarms. The entity the reference numbers and dimensional ranges will be determined on the basis of the type of machine and the degree of safety required by the customer.

And. If the concentration of particles C in the fluid on the basis of the time span X is between Crif1 and Crif2 (2? <= C <= 3 ?, default setting Crif1 = 2? And Crif2 = 3? Where? Corresponds to the value of the standard deviation), the medium level alarm? High concentration of ferromagnetic metal particles in the fluid in the time frame X? sar? stored by the microcontroller in the list of alarms. The values of Crif1 and Crif2 will be determined according to the type of machine and according to the degree of safety required by the customer.

f. If the concentration of particles C in the fluid on the basis of time frame X is higher than Crif2 (C> 3?), The high level alarm? Critical concentration of ferromagnetic metal particles in the fluid in time frame X? sar? stored by the microcontroller in the list of alarms.

g. If the total mass of the ferromagnetic metal particles Mf calculated from the last reset of the meters exceeds the reference value Mfref1 (Mf> Mfref1), the high level alarm? Critical wear level reached by the machine? sar? stored by the microcontroller in the list of alarms. The value of Mfrif1 will be? determined according to the type of machine and according to the degree of safety required by the customer.

6.2 VIBRATIONS PRODUCED BY THE CONTROLLED MACHINE:

The vibration measurement on the controlled machine will come? performed by installing a certain number of vibration sensors in pi? strategic points of the machine to be controlled. The number and installation position of the sensors in question will be defined according to the type of machine to be controlled and according to the level of safety required by the customer.

Through the analysis of the vibrations it will be? possible to detect any damage to the bearings and / or other mechanical parts, cos? as any imbalances of the rotating parts which, in these conditions, will cause anomalous vibrations.

Based on the data detected by the vibration sensors installed and based on their location, various medium and high level alarms can be detected and stored by the microcontroller in the alarm list.

Below are some examples of medium-level alarms that can be detected by positioning at least one sensor in at least one strategic position on the controlled machine:

? ? Slight crankshaft imbalance ?.

? ? Anomalous vibration of slight entity? on bearing number N ?.

? ? Abnormal vibration on reduction gear N ?.

? etc?

Here are some examples of high-level alarms that can be detected by positioning at least one sensor in at least one strategic position on the controlled machine:

? Critical unbalance of the crankshaft. Stop the machine immediately to avoid catastrophic breakdowns ?.

? ? Abnormal vibration of serious entity? bearing number N. Stop the machine immediately to avoid catastrophic breakdown ?.

? ? Abnormal vibration of serious entity? on the reduction gear N. Stop the machine immediately to avoid catastrophic breakdowns ?.

? etc?

It is pointed out that the above alarm lists do not represent in any way the totality. of the possible alarms signaled by the multi-control system and consequently do not in any way limit the protection of this patent application to the alarms listed above.

6.3 INSTANTANEOUS POWER ABSORBED BY THE CONTROLLED MACHINE

6.3.1 CALCULATION OF THE ELECTRICAL AND / OR MECHANICAL POWER ABSORBED BY THE CONTROLLED MACHINE

During this phase the microcontroller will provide? to the calculation of the instantaneous power absorbed by the machine to be controlled. If the machine to be checked is electric, the calculation will come? carried out using the values detected by the electric current and electric voltage sensor (s); if the machine to be checked is mechanical, the calculation will come? carried out by means of the values detected by the torsion / torque sensor / s and by the rpm sensor / s (RPM) or directly by means of the signal detected by the actuator, depending on the type of mechanical machine in question.

The calculated power? a parameter of fundamental importance to determine the exploitation of the controlled machine. Under certain conditions, such as the starting of the machine, it will be? it is necessary to check that the power does not exceed a certain maximum value Pmax. Should this value be exceeded during start-up, the high-level alarm? Excessive load during start-up? sar? stored by the microcontroller in the list of alarms.

The instantaneous power parameter will act? also supports the assessment of the severity? of the alarms detected by the metal particle sensor. As an example, we cite the following cases:

? Detection of high-level alarms relating to the increase in the count and / or concentration of ferromagnetic and / or non-ferromagnetic metal particles in the lubricating fluid in conjunction with a very high instantaneous power absorbed by the controlled machine (above a value Plim limit set based on the type of machine and based on the level of security required by the customer).

In this case the level of the alarm will not come? raised to the critical level as the alarms relating to metal particles may reasonably be attributable to the high load of the controlled machine. The level of the alarm will come? in any case, kept high as alarms relating to metal particles have always and in any case a certain value.

? Detection of high-level alarms relating to the increase in the count and / or concentration of ferromagnetic and / or non-ferromagnetic metal particles in the lubricating fluid in conjunction with a low instantaneous power absorbed by the controlled machine below a Plim2 limit value set according to the type of machine and according to the level of security required by the customer).

In this case the level of the alarm will come? raised to the critical level as the alarms relating to metal particles can reasonably be attributed to a structural problem that could result in entity? very important. At the end of the text of the metal particle alarms in question will come? added the phrase? Power absorbed low ?, to better signal the gravity? alarm.

6.4 CALCULATION OF THE WORKING HOURS OF THE CONTROLLED MACHINE

The microcontroller will be? configured to store the count of the working hours of the controlled machine elapsed since the last reset. The zeroing will go? carried out manually at the customer's discretion, generally at the end of general reviews.

Will the count of the working hours of the controlled machine be based? on the detection of the electrical or mechanical power of the controlled machine, in particular the count will be? active in the event that the power of the machine is higher than a certain minimum threshold value (Pmin) and sar? stopped in the event that the value of the power of the machine is lower than said minimum threshold value.

7. SIGNALING OF ALARMS

When the microcontroller will have? finished the data processing phase, the list of alarms will be? been completed and the level of the alarm will be? been defined.

It should be noted that the alarms and types of signals that will be described below may be acoustic and / or luminous and / or visual, in particular the acoustic warning may? be modulated according to the degree of alarm: low, medium-high and the visual warning can? be displayed on the system display positioned outside the control box (7), or even on a remote control computer / tablet / smartphone etc. This method will be able? also be implemented with a method that is implemented by an appropriate software to be installed not only in the system (in particular in the microcontroller) but also on appropriate computers, servers, and also be implemented by an application for smartphone, tablet or other.

The examples of light, visual and acoustic signaling of the alarms and the alarm level shown below do not represent in any way the totality of the alarms. of those configurable on the innovative multi-control system and consequently do not in any way limit the protection of this patent application to the cases listed below.

If the system is equipped with devices, installed on the container reserved for the electrical part, for the luminous and / or acoustic signaling of the alarm level and / or visual of the alarms and parameters detected by the sensors, the microcontroller will provide? to turn on the luminous and / or acoustic signaling device pi? appropriate based on the alarm level detected and will provide? to display the list of alarms detected and the value detected by certain sensors on the visual device positioned outside the control box (7), such as screen / HMI panel / monitor etc.

The choice of sensor values to be visually displayed will be? fully customizable according to customer needs.

An example (not binding) of light and acoustic signaling could be the one shown below:

? If the list of alarms is empty, the green light signaling device will come? on steadily and no acoustic signaling device will come? activated.

? If the alarm level is of medium type, the yellow luminous signaling device will come? lit steadily and the medium-level acoustic signaling device will come? activated.

? If the alarm level is high, the red light signaling device will come out. steadily lit and the high-level acoustic signaling device will come? activated.

? If the alarm level is critical, the red light signaling device will come out. intermittently lit with a very high blink rate and the high-level beeper will sound. activated.

The system, according to the needs, can? also be equipped with a test button for luminous display devices, a switch to mute one or more? acoustic signaling devices and a biometric and / or magnetic card and / or numeric code recognition device, etc? for the management of authorizations.

Always according to the needs, the system can? be programmed to request the acknowledgment / acceptance of all reported alarms, in order to ensure that system end users are aware of all reported alarms, including those that have gone back on their own without the need? to carry out any intervention.

For particular functions, where present, such as for example but not only the silencing of the acoustic alarms, the acknowledgment of the alarms or the display of certain values detected by the sensors, the system can? be set to require certain permission levels.

If the system is modulated to signal the alarms and / or the alarm level and / or the list of alarms and / or the values detected by certain sensors on a remote control computer / tablet / smartphone, etc., will the microcontroller provide? to transfer the information of interest through the transfer method pi? appropriate (such as SQL QUERY, FTP, FTPS, TCP, Stream Analytics, etc.?) can be determined based on the customer's needs.

Should the system be modulated to interact with the management system of the plant of which the machine to be controlled is part (such as the on-board system of a ship, the management system of a refinery or an offshore platform, etc.? ), the microcontroller will provide? to communicate the parameters of interest to the system in question through the method of connection and transfer pi? appropriate, which can be determined based on the needs and software / hardware used by the customer.

8. DATA SAVING

The microcontroller will be? programmed to save at least the sensor data, the alarms, any reports of scheduled maintenance interventions and their completion, generic events such as the switching on and off of the controlled machine, the self-diagnostic alarms and the number of working hours of the machine controlled in one or more? database, whose location, memory, encryption level, access authorization, speed? of access and limit of simultaneous connections can be modulated according to the customer's request.

Possible examples of database placement, which in no way represent the whole? of the possible solutions that can be adopted by the innovative multi-control system and consequently do not in any way limit the protection of this patent application to the following, can be:

? Location of the database inside the memory of the microcontroller and / or the HMI panel, if present. It is obvious that the performance and memory of that database will result? be limited based on the characteristics of the microcontroller and / or HMI panel used.

? Placement of the database on a computer connected remotely or belonging to the network where? placed the innovative multi-control system.

? Placement in servers belonging to the network where? placed the innovative multi-control system.

? Placement in cloud server.

9. FINAL CONCLUSIONS

In conclusion, it is observed that the system, the product and the method described by the present invention allow an effective and effective prediction, prevention and planning of the maintenance relating to machines and / or devices having grease lubrication.

The system, the product and the method, described by the present invention, thanks to its constant and continuous monitoring action of the metal particles that identify the wear, allow to maximize as much as possible. can the operation? and the availability? of the controlled machines in full compliance with the requirements of use and within the limits established by the specifications and characteristics defined by the manufacturers of the machines themselves.

In the embodiment examples previously illustrated, single characteristics, reported in relation to specific examples, may actually be interchanged with other different characteristics, existing in many other possible examples of realization.

The system, the product and the method described by the present invention are susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept expressed in the attached claims. All the details can be replaced by other technically equivalent elements, and the materials can be different according to the requirements, without departing from the scope of the invention.

In further embodiments, the arrangement and therefore also the reciprocal positions and the selection of how many and which sensors and / or how many and which components of the system, product and method described in the present invention can vary according to their use and choice of customers.

Furthermore, the communication of the sensors provided with the system and with the product described by the present invention, can? be carried out, not only via cable, but also with a wireless system (wireless), such as in Wi-Fi and / or with any other method of wireless communication.

Even if the system, the product and the method have been described with particular reference to the attached drawings, the reference numbers used in the description and in the claims are used to improve the intelligence of the invention and do not constitute any limitation to the scope of protection claimed. .

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DRAWING 4

Claims (1)

CLAIM 1 With reference to figures 1, 2, 3 and 4 (to which all the numerical references shown in this document will be referred),? a schematic representation of a preferred embodiment of the multi-control system for grease lubricated machines and related method described by the present invention: in particular such system will be represented. composed of: ? at least a truncated cone (2) (or any other regular geometric shape) pi? or less large and more? or less high depending on the size of the gears to be lubricated; ? at least one parallelepiped-shaped tray (3), also of variable dimensions according to the dimensions of the gears; ? at least one level sensor (4); ? at least one motor-pump unit (5); ? at least one control box (7) containing in turn at least one? unit? programming / microcontroller, such as a PLC and / or any other programmable input-output card and / or any other programmable microprocessor; at least one control panel, such as for example a display, an HMI panel, a monitor and / or any other type of communicative screen; ? at least one device for data transmission from the unit? programming / PLC microcontroller to one or more? databases located locally and / or in the cloud and / or to interact with the management system of the plant of which the machine to be controlled is part (such as the on-board system of a ship, the management system of a refinery or of an offshore platform, etc.). ? at least one sensor for detecting the temperature of the lubricating fluid, with pre-set alarms when the threshold defined by the grease dropping point is exceeded; ? at least one sensor for detecting both ferrous (magnetic) and non-ferrous (non-ferrous) metal particles (6) in the lubricating fluid, with alarms set when pre-set thresholds are exceeded, determined by the type of machine and the way and field of use. Thresholds will be set not only for the number and size of particles, but also for the calculated instantaneous values of their concentration (generally measured in micrograms or milligrams per liter) and the total mass value (generally in grams). The total mass value of the particles will be? identified as the entity? of the absolute wear suffered by the controlled machine up to that particular moment; ? at least one sensor for the detection of the percentage of humidity? relative in the lubricating fluid with alarm thresholds determined on the basis of the fluid specifications and the degree of protection chosen by the customer; ? at least one sensor for the detection of simple and complex vibrations of the controlled machine with alarm thresholds based on the type of and the mode and field of use of the controlled machine, appropriately filtering and cataloging the operational vibrations produced by the controlled machine and / or the • surrounding environment and / or external factors and / or other machines or devices operating within the range of action and / or any other type of source; ? at least one sensor for detecting the instantaneous power absorbed by the controlled machine with alarm thresholds determined by the specifications of the manufacturer of the controlled machine; ? at least one sensor for the detection of the external ambient temperature used to support the other sensors to better evaluate the gravity? of any specific alarms encountered. CLAIM 2 Control system of the operation? and maintenance of grease lubricated machines according to the preceding claim 1, which is also capable of evaluating the combination of the alarms detected by defining their criticality level. In this regard, we want to mention some preferred examples of combined alarms deriving from different parameters: ? Detection of alarms relating to the increase in the number and / or concentration of ferromagnetic and / or non-ferromagnetic metal particles in the lubricating fluid in conjunction with a low instantaneous power absorbed by the controlled machine (below a limit value set according to the to the type of machine and according to the level of safety required by the customer). This alarm signals a structural problem that could be of entity? very important considering the low value of power absorbed by the controlled machine; ? Detection of alarms relating to the increase in the number and / or concentration of ferromagnetic and / or non-ferromagnetic metal particles in the lubricating fluid in conjunction with high level vibration alarms on the controlled machine in conjunction with a low instantaneous power absorbed by the machine controlled (below a limit value set according to the type of machine and according to the level of safety required by the customer). The combination of these alarms signals with great probability? a structural problem of entity? very important that could easily lead to catastrophic breakdowns if sudden checks and maintenance interventions were not carried out. In this case, operators would be required to stop the controlled machine immediately. CLAIM 3 Control system of the operation? and maintenance of grease lubricated machines according to all previous claims 1 and 2, able to manage and recommend the external use of an optional infrared camera for the evaluation of the level of gravity. of the alarms, which would be able to immediately locate an area of greater heat (for example a single bearing or a single gear) as the probable source of a failure / breakage; CLAIM 4 Control system of the operation? and maintenance of grease lubricated machines according to all the preceding claims 1, 2 and 3, also able to manage and recommend the external use of an optional portable ultrasound meter, also useful for evaluating the level of gravity. of the alarms, which would be able to immediately locate an? area of greatest? noise? (for example a single bearing) as the probable source of a failure / break; CLAIM 5 Control system of the operation? and maintenance of lubricated machines according to all the preceding claims 1, 2, 3 and 4 which, in addition,? equipped with a self-diagnostic program for reporting any internal failures, able to predict almost all? of possible internal problems of the control system itself; CLAIM 6 Control system of the operation? and maintenance of lubricated machines according to all the previous claims 1, 2, 3, 4 and 5, whose output, in addition, is suitable for being shared with any smartphone, palmtop, tablet, laptop or desktop device that can be connected to the Internet and not, in order to view and analyze all the data and information available to optimize the management of the machines. The Customer could view the operating and maintenance conditions of all its machines at the same time, and, always in real time, could receive immediate messages on the smartphone when serious failures occur on each of their machines; CLAIM 7 Control system of the operation? and maintenance of lubricated machines according to all the preceding claims 1, 2, 3, 4, 5 and 6, whose installation and use are, in addition, very simple and immediate. In addition to having the advantage of an extremely simple installation, it does not require any modification, even minimal, to the machine to be controlled, thus avoiding any customer concerns; CLAIM 8 Control system of the operation? and maintenance of lubricated machines according to all the previous claims 1, 2, 3, 4, 5, 6 and 7, able, moreover, to manage the scheduled / planned maintenance, understood as the set of checks and actions established by the manufacturers machines monitored for the execution of ordinary and extraordinary maintenance; CLAIM 9 Creation of an explosion proof model of the control system (1) of the operation? and maintenance of lubricated machines according to all the previous claims 1, 2, 3, 4, 5, 6, 7 and 8, very important for the use of the device in areas classified as dangerous due to the presence of highly explosive gases such as methane, ? acetylene etc ... CLAIM 10 Interconnection of an arbitrary number of control systems (1) of the operation? and maintenance of lubricated machines according to all the previous claims 1, 2, 3, 4, 5, 6, 7, 8 and 9, varying in number and type of sensors included in the system, able, in addition, to exchange and interpret the data collected and also able to simultaneously transmit all the data collected and processed in streaming and / or in special archiving databases.