JP2852965B2 - Refueling management system - Google Patents

Description

Description: BACKGROUND OF THE INVENTION The present invention relates to an oil supply management system, and is particularly suitable for supplying and managing lubricating oil and hydraulic oil to a large number of machines. The present invention relates to a refueling management system capable of detecting a machine abnormality / predicting a failure based on the information.

[Conventional technology]

The machine tool is provided with a lubricating oil tank having an oil level gauge and a distribution valve for supplying lubricating oil to the sliding part, so that a constant amount of lubricating oil is supplied to the sliding part at regular intervals. There is something. In general, hydraulic oil for a hydraulic system is stored in a hydraulic oil tank having an oil level gauge.

Conventionally, supply management of lubricating oil and hydraulic oil for this type of machine has been
Since the amount of oil consumption is relatively small, the operator occasionally monitors the oil level gauge visually, and when the oil level is low, an appropriate amount is supplied by a manual pot.

In the case where a large amount of oil is consumed, such as boiler fuel oil, an oil level sensor is provided in a service tank provided near the boiler, and the main tank is disposed so that the oil level of the service tank falls within predetermined upper and lower limits. Has supplied fuel oil by an oil supply pump device.

[Problems to be solved by the invention]

However, there is a problem in that visual monitoring takes time and effort. In particular, in recent years, one worker is often in charge of many machines, and the number of man-hours is not negligible.

Fluctuations in the consumption of lubricating oil and hydraulic oil often signal a machine failure. For example, an extreme decrease in lubricating oil consumption signals a seizure failure due to clogging of the distribution valve. Excessive oil consumption may indicate an abnormal increase in pump pressure or a leak in the hydraulic system. in spite of,
There is a problem that it is left to the operator's experience and intuition to detect these precursors and determine the abnormality of the machine.

The present invention has been made in view of the above problems,
The goal is to make it possible to find oil consumption abnormalities, which can be a sign of a machine failure, and to predict failures, while making the refueling management of many places virtually unmanageable. It is an object of the present invention to provide a refueling management system.

[Means for solving the problem]

In order to achieve the above object, according to the present invention, oil is supplied from a main tank to two or more service tanks provided for each machine from a main tank by an oil supply pump device. A refueling management system for performing failure prediction, comprising: a remote control valve provided for each of the service tanks for opening and closing communication between the service tank and the refueling pump device; and a at least lower limit position provided for each of the service tanks. Receiving the signal of the lower limit position from the oil level sensor and selectively driving the remote control valve to connect the service tank and the refueling pump device, and Selective refueling drive means for driving the refueling pump device to feed a fixed amount of oil,
A refueling amount storing means for accumulating the amount of oil supplied by the selected refueling driving means for each service tank, converting the refueling amount for each service tank, and storing the converted amount; Consumption calculating means for calculating the oil consumption of each machine, operating time storage means for accumulating and storing the operating time of each machine, and an appropriate amount of oil consumption per unit time of each machine. ) × (the operation time), an appropriate consumption amount calculating means for calculating an appropriate consumption amount of oil for each service tank, and an actual consumption amount of oil for each service tank and the appropriate consumption amount for each predetermined period. And an abnormal signal output means for outputting an abnormal signal when the deviation is equal to or more than a predetermined value, and an abnormal display means for receiving the abnormal signal and displaying an abnormality.

Here, “abnormality detection / failure prediction” means “abnormality detection”,
It is a word that includes “failure prediction” or “abnormality detection and failure prediction”.

Further, as the oil level sensor, a float and a reed switch are provided, and the position of the oil level can be quantitatively detected, and the reed switch is disposed obliquely to a liquid level change direction. The means for supplying a predetermined amount of oil may drive the oil supply pump device from when the oil level sensor detects a predetermined lower limit position to when it detects a predetermined upper limit position. Such an oil level sensor can detect the position of the oil level before and after oil feeding.

Alternatively, a positive displacement pump and a pulse motor may be used for the refueling pump device, and the pulse motor may be driven by a predetermined number of pulses after the oil level sensor detects the lower limit position.

Further, a consumption storage means for storing the oil consumption of the service tank for a predetermined period in the past, and an oil consumption of the service tank for the predetermined period in the past stored in the consumption storage means for each service tank. And a display means for displaying

[Action]

In the refueling management system configured as described above, when the amount of oil in the service tank decreases, oil is supplied by the selected refueling drive unit, and the amount of oil in the service tank is maintained in a certain range. Then, the actual oil sphere amount of each service tank (the actual oil consumption amount of each machine) is calculated, and abnormality detection / failure prediction is performed based on comparison with the appropriate consumption amount.
If there is an abnormality, an abnormality is displayed. For this reason,
An abnormality of each machine can be detected at an early stage, and the damage can be prevented from being expanded by the abnormal operation by predicting the failure.

〔Example〕

Embodiments of the present invention will be described with reference to the drawings. First
The figure is a configuration diagram showing a refueling management system. This refueling management system is a system (apparatus) for supplying and managing lubricating oil to many machines.

For simplicity, FIG. 1 shows two machines 1, 1b (further,
Although only one service tank 2 and 2b is shown for each machine 1c) and each machine 1 and 1b, in an actual system, tens to hundreds of machines are connected, and each machine has It has a large system configuration with dozens of service tanks attached.

Each machine 1, 1b is provided with a service tank 2, 2b, respectively, and lubricating oil stored in the service tank 2, 2b is pumped to the distribution valves 4, 4b by pump motors 3, 3b, and from the distribution valves 4, 4b. Pipes are provided so that small amounts of oil are supplied to sliding parts, rotating parts, joint parts, etc. of the machines 1 and 1b. The pump motors 3, 3b are connected to and controlled by the lubrication controllers 5, 5b. The lubrication controllers 5, 5b receive the machine power signal from the machines 1, 1b, and receive the pump motors 3, 5, every predetermined time or every predetermined cycle of the machine.
Drive 3b. The structure so far is the same as the conventional lubricating oil supply device.

In this embodiment, the service tanks 2, 2b
Is supplied with lubricating oil. That is, a pipe 12 is provided from the main tank 10 to each service tank 2, 2b via the refueling pump device 11, and each service tank 2, 2b
Has a solenoid valve (remote control valve) that opens and closes communication with the pipe 12,
6b is provided. A pressure sensor 13 is connected to the pipe 12.
The service tanks 2, 2b and the main tank 10 are provided with oil level sensors 7, 7b, 14, and temperature sensors 8, 8b, 15, respectively.

Oil level sensors 7, 7b, and 14 are high-sensitivity sensors that use magnet floats and reed switches.They always detect the oil level, not just the upper and lower limits, and output a signal that corresponds to the position of the magnet float at any position. . In the oil level sensors 7, 7b, 14, a plurality (for example, five) of reed switches are arranged obliquely along the direction of change in the liquid level, but the arrangement is not limited to this. .

For the refueling pump device 11, a gear pump, which is a positive displacement pump, and a pulse motor are used. The refueling pump device 11 and the solenoid valves 6, 6b are connected to the control device 50 and drive-controlled. The control device 50 is a device generally called a sequencer.

In addition to the output signals from the sensors 7, 8, 13, 14, and 15, the control device 50 receives machine power signals from the machines 1 and 1b. The control device 50 is connected to the computer 51. The computer 51 is a small computer called a personal computer, and is a well-known computer having a CPU, a ROM, a RAM, and the like. A keyboard 52, a display device (CRT) 53, and a printer 54 are connected to the computer 51.

Further, a warning light 55 provided near the machines 1 and 1b is connected to the control device 50.

FIG. 2 is a flowchart showing the processing in the control device 50. When the process is started, first, in step 101, scanning for sequentially reading signals of the oil level sensors 7, 7b of the respective machines 1, 1b is performed. Next, in step 102, one of the oil level sensors 7, 7b detects the lower limit position, and determines whether or not refueling is required. If not, the process returns to step 101, and if so, the process proceeds to step 103. In step 103, the solenoid valves 6, 6b of the machines 1, 1b for which refueling is required are excited to open, and in the next step 104, the refueling pump device 11
Start Next, in steps 105 and 106, the number of pulses driving the pulse motor of the refueling pump device 11 is counted, and the process waits until the counted number of pulses reaches a predetermined value. When the predetermined value is reached, the process proceeds to steps 107 and 108, and the fuel supply pump device 11 is stopped, and the electromagnetic valve 6,
The excitation of step 6b is stopped to close.

The processing from step 101 to step 108 is performed by receiving the signal of the lower limit position from the oil level sensors 7, 7b, and selectively connecting the service tanks 2, 2b and the refueling pump device 11 with the electromagnetic force. In addition to driving the valves 6 and 6b, a selective oil supply driving unit that drives the oil supply pump device 11 to supply a predetermined amount of oil is provided.

Hereinafter, data transfer to the computer 51 is performed. In steps 109 and 110, the state of the computer 51 is checked, and the system waits for the reception state. In the reception state, the process proceeds to step 111, where the numbers of the machines 1, 1b that have refueled and the number of pulses that have driven the pulse motor of the refueling pump device 11 are transferred. In steps 112 and 113, a reception completion signal is received from the computer 51. When the reception completion signal is received, the process proceeds to step 114. In step 114, it is checked whether or not the processing is completed. If not, the process returns to step 101.

FIG. 3 is a flowchart showing the processing in the computer 51. Here, the processes to be executed in step 201 and steps 203 to 206 are selected, and the respective processes 210 to 250 are executed.

When there is an input request from the control device 50, the process proceeds from the step 201 to the input process 210, and the input process 210 shown in FIG. 4 and the abnormality detection process 220 shown in FIG. 5 are sequentially executed.

In the input device 210 shown in FIG. 4, first in step 211,
Data transfer from the control device 50 is accepted, and in the next step 212, the number of transferred pulses is converted into a refueling amount.
Next, at step 213, the refueling amount is added to the previous data of the service tank in the refueling data accumulation file and stored. The refueling data accumulation file stores, for each service tank, accumulated refueling amount data for a predetermined period, for example, every day.

Next, in the abnormality detection process 220 shown in FIG.
In step 21, the lubricating oil consumption for a predetermined period, for example, every day or every month, is calculated from the lubrication amount data of the lubrication data accumulation file, and in the next step 222, the consumption is displayed on a display device (CR).
T) Display at 53. In step 223, the operation time of each mechanism 1, 1b is accumulated and stored. The operation time can be integrated by the machine power signal from each machine 1, 1b. Step 224
Then, from the operation time for each predetermined period, each service tank
Calculate the appropriate oil consumption for each 2,2b.

This “appropriate consumption of oil in each service tank 2, 2b for a predetermined period” is “(appropriate consumption of lubricating oil per unit operating time of each machine 1, 1b) × (actual consumption of oil in each machine 1, 1b). Operating time). " That is, the consumption amount of the lubricating oil per unit operating time of each machine 1, 1b is constant as long as the machine is operating normally. Is the consumption of the lubricating oil of each machine 1, 1b per unit time in its normal operation. And (actual operating time of each machine 1,1b)
Is obtained in step 223.

In step 225, each service tank 2, 2b
The deviation between the oil consumption and the proper consumption for each is calculated. In step 226, the deviation is a predetermined value, for example, ± 40
% Or more, and if it is more than a predetermined value, step 22
Proceeding to 7, the lubricating oil abnormality is displayed on the display device (CRT) 53, and in step 228, an abnormality signal is output to the control device 50 to turn on the alarm lamp 55. On the other hand, when the deviation is equal to or smaller than the predetermined value, the processing 220 for the predetermined time is ended as it is.

When the daily work menu is instructed from the keyboard 52, the process proceeds from step 203 to process 230, where the daily work process 23 is executed.
0 is executed. In the daily work processing 230, according to the selection from the keyboard 52, the print display of the inspection refueling list, the print display of the oil leak worst list, the print display of the refueling amount transition graph,
Execute oil change data input, print display of oil change list, etc. Here, the check refueling list is for each service tank 2,
The table shows the daily refueling amount in numerical order of 2b. The list of worst oil leaks is listed in descending order of refueling amount.

As shown in FIG. 6, the refueling amount transition graph shows a change in the refueling amount per day or once during a predetermined period, for example, the past three months. In the figure, 61 indicates the amount of refueling per day, 62 indicates the average value, 63 indicates the upper limit deviation value, and 64 indicates the lower limit deviation value. Since the change in the amount of refueling becomes clear at a glance, it is extremely easy to predict a machine abnormality or failure. Oil change data input is an input for keeping the data when oil is changed.

Further, when the monthly work menu is instructed from the keyboard 52, the process proceeds from step 204 to processing 240, where the monthly work processing 24
0 is executed. In the monthly business process 240, according to the selection from the keyboard 52, the print display of the inspection refueling statistics table, the print display of the statistics table for each part, the print display of the oil type statistics table, the print display of the oil leak worst list, the HFI worst list Print display,
The printout of the target place total table by use, the printout of the oil consumption change graph by workplace, the printout of the oil leak worst oil supply total change graph, etc. are executed. Here, the HFI (annual refueling index) is an index obtained by dividing the refueling amount for a predetermined period by the capacity of the oil tank.

When the term-end task menu is instructed from the keyboard 52, the process proceeds from step 205 to term-term task processing 250, where term-term task processing 250 is executed. In the term-end business process 250, a statistical table and a transition graph similar to those in the table of contents business menu are printed and displayed based on the data for one year.

In step 206, it is checked whether or not the process is completed. If not, the process returns to step 201.

In the above-described embodiment, a positive displacement gear pump and a pulse motor are used for the refueling pump device 11, and the pulse motor is driven by a predetermined number of pulses after the oil level sensor 7 detects the lower limit position. The motor of the oil supply pump device 11 may be driven from when the lower limit position is detected until the upper limit position is detected. In this case, a normal AC induction motor can be used.

Although the lubricating oil supply management system has been described in the embodiment described above, the device of the present invention is not limited to lubricating oil,
It is clear that the present invention can be applied to hydraulic oil and cutting oil. When used for hydraulic system hydraulic oil, it is possible to accurately determine whether or not the hydraulic system should be repaired by estimating the annual loss amount from the display of the worst oil leakage list. Further, as the oil level sensor, other types of oil level sensors can be used instead of the float / reed switch type.

Furthermore, the oil temperature of the hydraulic oil is constantly detected by the temperature sensors 8 and 8b, and when the temperature exceeds a predetermined temperature (for example, 50 to 60 ° C), an alarm light is turned on.
Displaying at 55 makes it easier to find an abnormality in the hydraulic system. In addition, when this temperature sensor is combined with an oil level sensor, the accuracy of oil management is further improved. Further, other management items (for example, the degree of contamination of oil) can also be managed.

〔The invention's effect〕

The refueling management system according to claim 1 has an excellent effect that refueling management of a large number of machines, for example, tens to hundreds of machines, can be easily performed without human intervention. In particular, the greater the number, the more this effect is exhibited.

Further, the refueling management system according to the first aspect makes it possible to detect the abnormality of the machine and predict the failure by comparing the actual consumption of the oil with the appropriate consumption. In addition, there is an excellent effect that it is possible to prevent the damage caused by the abnormal operation from spreading.

In the refueling management system according to the second aspect, the selected refueling drive unit drives the refueling pump device to send a predetermined amount from when the oil level sensor detects the predetermined lower limit position to when the oil level sensor detects the predetermined upper limit position. Oil. For this reason, anything other than a pulse motor, for example, an AC induction motor, can be used as the driving means of the refueling pump device.

The selective refueling drive means starts oil supply after the oil level falls below the lower limit, and stops oil supply after the oil level exceeds the upper limit. For this reason, when the oil level sensor detects only the upper limit and the lower limit, it is not possible to detect an accurate refueling amount. However, in the refueling management system according to the second aspect, the oil level sensor can quantitatively detect the position of the oil level, and can detect the position of the oil level before and after oil supply. The amount of refueling can be accurately detected from the difference between the positions of the oil levels measured quantitatively.

In the refueling management system according to claim 2,
Since the reed switch of the oil level sensor is arranged at an angle to the liquid level change direction, it can detect minute changes more accurately than when it is arranged in the liquid level change direction (perpendicular to the liquid level). Can be.

Therefore, in the refueling management system according to the second aspect, in a refueling management system that accumulates an actual oil supply amount (consumption amount) and compares the actual oil supply amount (consumption amount) with an appropriate consumption amount at regular intervals, disturbance caused by accumulation of errors is reduced. And accurate comparisons can be made.

In the refueling management system according to claim 3, the refueling pump device has a positive displacement pump and a pulse motor, and the selective refueling drive means drives the pulse motor by a predetermined number of pulses after the oil level sensor detects the lower limit position. Means for feeding a predetermined amount of oil. Therefore, the amount of refueling can be accurately controlled based on the number of pulses. Therefore, in a refueling management system that accumulates the actual oil supply amount (consumption amount) for each predetermined period and compares the actual oil supply amount (consumption amount) with the appropriate consumption amount, disturbance due to accumulation of errors can be reduced, and accurate comparison can be performed. it can.

According to a fourth aspect of the present invention, there is provided a refueling management system including a consumption storage unit that stores a consumption amount of oil in a past predetermined period for each service tank, and a display unit that displays the consumption amount. For this reason, in each of the past periods, even if the deviation between the actual consumption of oil and the appropriate consumption is within the specified value and no abnormal display is made, the actual consumption of oil that changes within the range is listed. And a longer-term machine failure prediction is possible.

[Brief description of the drawings]

1 shows an embodiment of the present invention, FIG. 1 is a configuration diagram of a refueling management system, FIG. 2 is a flowchart showing processing in a control device 50, and FIGS. 3, 4, and 5 are computers 51.
3 is a flowchart showing processing to be executed in each of steps 201 and 203 to 206, FIG. 4 is a flowchart showing execution of input processing, and FIG. FIG. 6 is a screen diagram showing a display example of a refueling amount transition graph displayed on the display device (CRT) 53. 1,1b ………………………………………………………………………………………………………………………………………… Machine equipment, 2,2b …… Service tank, 6,6b …… Solenoid valve (remote control valve), 7,7b …… Oil level sensor, 8,8b …… Temperature sensor, 10 …… Main tank , 11… Refueling pump device, 12… Piping, 50… Control device (sequencer), 51…
... computer, 53 ... display device (CRT).

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-61-286698 (JP, A) JP-A-2-106250 (JP, A) JP-A-63-75374 (JP, A) JP-A 61-86374 142193 (JP, A) Japanese Utility Model 63-79141 (JP, U) Japanese Utility Model Hei 2-76298 (JP, U) Japanese Utility Model Utility Model 62-78246 (JP, U) (58) Fields surveyed (Int. ⁶ , DB name) F16N 29/00

Claims (4)

(57) [Claims] An oil supply management system that supplies oil from a main tank to two or more service tanks provided for each machine by an oil supply pump device, and detects a machine abnormality / failure prediction based on the oil supply amount. A remote control valve provided for each of the service tanks for opening and closing communication between the service tank and the refueling pump device, and an oil level sensor provided for each of the service tanks and capable of detecting at least a lower limit position Receiving the signal of the lower limit position from the oil level sensor, and driving the remote control valve to selectively connect the service tank with the refueling pump device, and sending a predetermined amount of oil. A selective refueling drive unit for driving the refueling pump device; and an oil supply amount by the selective refueling drive unit is accumulated for each service tank, and refueling is performed for each service tank. Refueling amount storing means for converting the amount of oil to be stored, consumption amount calculating means for calculating an actual oil consumption amount for each service tank from the refueling amount at predetermined intervals, and accumulating the operating time for each machine Operating time storage means for storing and storing an appropriate amount of oil for each service tank at predetermined intervals by (appropriate amount of oil consumption per unit time for each machine) × (operating time) A consumption calculating means, an abnormality signal for calculating a deviation between the actual oil consumption and the appropriate consumption for each service tank for each of the predetermined periods, and outputting an abnormality signal when the deviation is equal to or more than a predetermined value A refueling management system comprising: output means; and abnormality display means for receiving an abnormality signal and displaying an abnormality. 2. The refueling management system according to claim 1, wherein the oil level sensor includes a float and a reed switch, and can detect a position of the oil level quantitatively. The selected oil supply drive means drives the oil supply pump device until the oil level sensor detects a predetermined lower limit position and then detects a predetermined upper limit position, and adjusts a predetermined amount. A refueling management system, comprising: means for feeding oil; wherein the oil level sensor can detect a position of an oil level before and after oil feeding. 3. The refueling management system according to claim 1, wherein the refueling pump device has a positive displacement pump and a pulse motor, and the selective refueling driving means has a predetermined pulse after the oil level sensor detects a lower limit position. A refueling management system comprising means for driving the pulse motor by a number to feed a predetermined amount of oil. 4. The refueling management system according to claim 2, wherein the consumption storage means for storing the consumption of oil for a predetermined period in the past for each of the service tanks; A display means for displaying the amount of oil consumed for a predetermined period in the past for each of the service tanks.