Patent Grant
9920878
The present disclosure generally relates to a lubrication system. More particularly, the present disclosure relates to a lubrication system having a lubrication controller that can be configured through firmware to selectively control multiple types of lubrication systems.
The present invention provides a lubrication system having a lubrication controller that can be configured through firmware to selectively control multiple types of lubrication systems. There are two basic uses for the system and controller that include both industrial and mobile applications. The first application has AC noise protection and output relays designed for the industrial market. The latter application includes DC noise protection and output relays designed for the mobile market.
As disclosed in the “Handbook of Lubrication and Tribology,” Volume 1 Application and Maintenance, 2nd Edition, the purpose of lubrication is to prevent metal to metal contact between two moving members, reduce friction, remove heat, and flush out contaminants. The philosophy of an automatic lubrication system is to deliver the right amount of lubricant at the right time. The method to do this is to deliver small quantity of lubricant to a bearing often. The lubricant is delivered in small portions as the bearing consumes it. Applying more lubricant than the bearing can consume in a short period of time is often thrown off the moving components, causing housekeeping and environmental safety hazards. A properly designed automatic centralized system can deliver just the right amount of lubricant the bearing needs.
The purpose of any centralized lubrication system is to provide the correct amount of grease to the bearing at the right time. The method to do this is for a controller to turn on a pump that supplies grease to positive displacement valves that will dispense a predetermined amount of grease to a bearing. The monitoring of system performance is key. This can be done with simple visual indicators or transducer feedback.
The present invention accomplishes the key component of monitoring a properly designed centralized lubrication system through the use of a novel multi-configurable controller that enables an end user to select a single piece of controller hardware and configure it via firmware for their specific application.
The basic inventive concept provides a lubrication system for lubricating bearings.
A first aspect of the present invention provides a lubrication system comprising:
at least one lubrication pump for pumping lubricant to the bearings, and
at least one metering valve for distributing the pumped lubricant throughout the lubrication system to the bearings, and
a lubrication controller in communication with the at least one lubrication pump and at least one metering valve for controlling the lubrication system and having firmware configured to provide a sequence of instructions to perform specified tasks and hardware that carries out the sequence of instructions to perform the specified tasks, and wherein
in an unconfigured and unconnected state, the lubrication controller can be configured by reprogramming the firmware to selectively control at least one of a series progressive lubrication system, a dual line lubrication system and a single line parallel lubrication system.
In a second aspect of the present invention the controller includes a USB port used to reflash the firmware.
In a third aspect of the present invention the lubrication system further includes at least one flow sensor and at least one pressure sensor, the flow and pressure sensors for sending feedback signals to the controller.
In another aspect of the present invention the controller is responsive to the respective flow and pressure sensor feedback signals and provides instructions to the lubrication pump and the at least one metering valve based on the feedback signals.
In yet another aspect of the present invention the lubrication system has at least one I/O device configured to interface with another information processing system and a power supply to drive the lubrication controller and the at least one I/O device.
In yet another aspect of the present invention the lubrication system providing a computer remotely connected to the lubrication controller and including PC software loaded into the computer, the PC software and computer combination used to both simulate the lubrication system and program the lubrication system.
In yet another aspect of the present invention the computer is used to download a history data log of the lubrication system.
In yet another aspect of the present invention the I/O device accommodates multiple inputs and multiple outputs.
In yet another aspect of the present invention the multiple inputs include at least one of a pressure sensor/transducer at pump, a pressure sensor/transducer at end of line, a low level, a count switch, a remote manual lube, a standby/ignition switch and a secondary timer.
In yet another aspect of the present invention the multiple outputs include at least one of a post spray, an air to pump solenoid and an alarm.
In yet another aspect of the present invention the lubrication controller further provides at least one communication port, the communication port to be used to connect with at least one of a remote sensor controller and a slave controller.
In yet another aspect of the present invention the lubrication system further includes the air valve being connected to the controller, and wherein the lubrication controller sends signals to the air valve to open and close.
In yet another aspect of the present invention the at least one valve provides at least one of a dual line metering valve and a change over valve.
In yet another aspect of the present invention the lubrication controller further provides an In-Cab display.
In yet another aspect of the present invention the communications port may be used for I/O expansion.
In yet another aspect of the present invention the communications port may be used for the remote controller to monitor bearings using lube sensors.
In yet another aspect of the present invention the communications port can integrate with factory automation systems.
In yet another aspect of the present invention the communications port can integrate with a PLC.
In yet another aspect of the present invention the In-Cab display further comprises:
at least two LED indicators for indicating low level and system failure,
an at least 3 digit display for selecting selected interval mode, timer operation, pump cycle and error codes, and wherein
the display can be used to set up a mode of operation, and wherein
the mode of operation set up includes at least one of a selection of a mode, a manual cycle and a reset system.
In a final aspect of the present invention a remote sensor controller may be connected to the lubrication controller, the remote sensor controller allowing the addition of extra lubrication sensors without expanding the size of the system lubrication controller.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Like reference numerals refer to like parts throughout the various views of the drawings.
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
A first embodiment of an inventive lubrication system 100 for lubricating bearings 140 is illustrated in
The lubrication system 100 also provides a basic low cost lubrication controller 110. Lubrication controller 110 controls the function of the lubrication system 100. Now referring to
The true value of the present invention is in the flexibility of the lubrication controller 110. The flexibility of the lubrication controller 110 lies in the firmware 112 that can alternatively be selected and the hardware 114 that comes standard with the controller 110. That is, the controller 110 can be programmed via the firmware 112 to selectively control multiple types of lubrication systems without changing the hardware 114. Furthermore, the hardware 114 selected is universal and can easily be added on to and built upon. This keeps the cost of the basic controller down, but allows for easy reconfiguration if desired. As described in the first preferred embodiment of
Basic Progressive Lubrication System 100 may also provide an air solenoid valve 150 and an air supply inlet assembly 160 that is in communication with air valve 150. Air supply inlet assembly 160 may further include a contaminant filter 200, a pressure regulator 210 and an air line lubricator 220 respectively connected together. A compressed air supply (not shown) is provided on an inlet side 205 of the air supply assembly 160. The air supply 160 drives the lubrication pump 120. The air solenoid valve 150 receives its commands to open and close from the lubrication controller 110.
Now referring to
A reciprocating piston 165 disposed within the lubrication pump 120 draws in lubricant (not show) during an inlet stroke of the lubrication pump 120. The lubrication, which is typically stored in a reservoir or tank, flows through a lubrication inlet port 230 and into a piston cylinder within the pump 120. The reciprocating piston 165 then drives the lubricant out of the piston cylinder through outlet 240 towards first divider metering valve 136 during an outlet stroke. The first divider metering valve 136 meters the lubricant in proper desired proportions to the last two divider metering valves 136. The last two divider metering valves 136 further meter the lubricant directly to the bearings 140 through bearing lubrication lines 137.
The desired lubrication system proportions are determined by the system design requirements and are either preset from the factory or adjusted during on-site system set up. The design requirements for proper bearing lubrication are determined by a number of factors. Those factors include, but are not limited to, the bearing RPM, run-time, temperature, vibration, size, orientation, amount of external contamination and load.
The divider metering valve 136 cycles back and forth while it meters and displaces the lubricant. An output volume provided by the displacement of the divider metering valves 136 determines the amount of lubrication that ultimately flows to the bearing(s) 140. The divider metering valves 136 can be cycled once or multiple times to deliver an appropriate amount of grease to the bearing(s) during an interval event. A cycle switch 180 is in mechanical communication with the first divider metering valve 136. The cycle switch 180 communicates the number of successive cycles the first metering valve 136 completes during the interval to the controller 110 via a cycle switch feedback line 190. This feedback allows the controller 110 to calculate whether the air solenoid 150 should be kept open longer to effect additional reciprocating piston 165 strokes. The number of piston 165 strokes in conjunction with the on-time selection programmed into the controller determines the total amount of lubrication delivered to the bearings 140.
The low cost controller 110 of Basic Progressive Lubrication System 100 requires a computer 370 to select the input programming parameters and lubrication programs. There is no operator interface or keypad/display in this embodiment. However, there are at least 2 LED indicators 270 for indicating the status of system conditions such as low level and system failure mounted to a front cover 273 of the controller 110. There are 4 LED indicators shown in this embodiment. The controller 110 may also include a manual lube push-button 275 for actuating a manual lube cycle by an operator.
The required computer 370 could be a laptop for ease of mobility or a PC that is remotely connected to the lubrication controller 110. The controller 110 also includes PC software 380 that is specifically designed for the controller 110. The PC software 380 is pre-loaded into the computer 370 before programming. The PC software 380 and computer 370 combination are used to both simulate the desired lubrication system configuration and program the simulated lubrication system configuration.
There is shown in
The operation of the Single Line Lubrication System 600 will now be disclosed. When lubricant is needed, the controller 110 opens the air solenoid 150 to turn on the pump 120. The pump 120 produces flow and builds up pressure in the line. When the pressure reaches a predetermined level, for example 1800 psig, one of the injectors 139 operates and meters a predetermined amount of lubricant to at least one bearing 140.
A pressure switch or transducer 345 usually located farthest away from the pump senses when the pressure has reached 1800 psig. Once the pressure is reached, the pressure switch or transducer 345 sends a signal via the pressure feedback line 346 to the controller 110 indicating that the system pressure was achieved. The controller then turns off the air solenoid valve and thus the air supply to the pump.
For pneumatically or hydraulically operated pumps, when the air/hydraulic supply is turned off, a 3-way valve 233 is activated, which directs any excess grease due to line expansion directly back to the reservoir through vent return port 234. For electrical operation, the controller 110 will shut off electric power to a 3-way vent valve 233. The pressure in the system can then be bled off venting the grease back to its reservoir.
When the lubrication system 600 is turned on, the 3-way valve is positioned to allow grease to flow to the injectors and thus to the bearings 140. After the injectors 139 have metered the correct amount of grease to the bearings 140, the system is shut off by the controller 110 turning off the pump. The 3-way valve is then shifted in a manner that bypasses the pump and redirects the grease back to the container, which is normally under atmospheric pressure only. This allows the line to bleed off the grease pressure or vent, thus allowing the injectors to reset and be ready for the next lube event. The vent valve can be operated pneumatically, hydraulically, or electrically depending on the power source that the pump uses. Each injector 139 can be manually adjusted to discharge the precise amount of lubricant each bearing needs.
A single injector 139 can be mounted to lubricate one bearing, or grouped in a manifold with feed lines supplying lubricant to multiple bearings as shown in
As shown in
In addition to the USB port 170 the controller may provide at least two communication ports 172 and 174. Communication port 172 may be used to monitor bearings using additional lube sensors via a flow sensor controller 490. Here, the flow sensor controller 490 detects if grease has reached the bearing. The remote sensor controller 490 allows the addition of extra lubrication sensors 180, 330, 340 and/or 350 without expanding the hardware of the main system lubrication controller 110. Alternately, communication port 172 can integrate with an I/O expansion controller. This allows an operator to control another pump or lubrication zone from the main controller 110. Communications port 174 can be used to communicate with factory automation systems or with a PLC 550 through a remote slave controller 500.
The I/O device 350 may accommodate multiple inputs and multiple outputs. The multiple inputs may include at least one of the pressure sensor/transducer at pump 340, a pressure sensor/transducer at end of line 345, a low level 400, a count/cycle switch 180, a remote manual lube 420, a standby/ignition switch 430 and a secondary timer 440. The multiple outputs include at least one of a post spray 450, the air solenoid valve 150 and an alarm 470.
The controller 110 also provides an In-Cab display 260 mounted on the front cover 273. In addition to the display 260, at least two LED status indicators 270 also mounted to the front cover 273, are provided to indicate low lubricant level and system failure. Here, the controller 110 provides 7 LED indicators and a manual lubrication push-button 275.
An at least 3 digit display 245 is provided for selecting the selected interval mode, timer operation, pump cycle and error codes. The display 260 can also be used to set up a mode of operation. The mode of operation set up includes at least one of a selection of a mode, a manual cycle and a reset system. The display 260 may also be used to obtain real time operation updates and alarm 470 notifications.
Here, user-programming can be accomplished two ways. The controller 110 can be programmed through the USB port 170 using the laptop computer 370 or the keypad display 260 located on the controller cover 273. There is both data logging and history reporting capability using the USB port 170 to laptop 370.
There is shown in
In Dual-Line system 700, the pump 120 supplies the lubricant to a change over valve 134. From the change over valve 134, lubricant is supplied alternately into one of the two main lines L1 and L2. Dual-Line systems 700 can be combined with progressive single line measuring valves 130 as well. Oil or viscous grease lubricants will function properly within this system. The Dual-Line lubrication system 700 works in two cycles. The central lubrication pump 120 supplies the lubricant under pressure to main line ML through the reversing 4-way valve. Main line L2 is connected to the reservoir. The metering valves 135 are connected to the main supply lines L1 and L2. The lubricant is dispensed under pressure from one side of the metering valves 135 to the point of application. As soon as the lubricant is dispensed from the last metering valve 135, the first half of the cycle is complete. The lubrication pump 120 will continue to operate, pressurizing the L1 line to the preset pressure. As soon as the preset pressure is reached, the change over valve 134 will switch the lubricant supply to the main line L2 connecting main line ML to the reservoir via return port 244.
Now, the pump 120 that supplies the lubricant under pressure to the main line L2. Line L1 is connected to the reservoir where the pressure is relieved. The lubricant will be dispensed from the metering valves to the at least one bearing 140. Second half cycle is complete as soon as the lubricant is dispensed from the last metering valve 135. The pump 120 will continue to operate until the preset pressure has been reached. At this point, a signal from the end-of-line pressure switch 340 or from a micro switch 342 on the change over valve 134 will stop the pump, turning the system 700 off.
There is shown in
There is shown in
As previously disclosed, the real value of the present invention is in the flexibility of the lubrication controller 110. The flexibility of the lubrication controller 110 lies in the firmware 112 that can alternatively be selected, and the hardware 114 that comes standard with the controller 110. That is, the controller 110 can be programmed via the firmware 112 to at least selectively control the preferred embodiments of lubrication systems without changing the hardware 114. Furthermore, the hardware 114 selected is universal and can easily be added on to and built upon. This keeps the cost of the basic controller down, but allows for easy reconfiguration if desired.
Since many modifications, variations, and changes in detail can be made to the five described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
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