CN112145946B - Automatic grease filling system and method for roller - Google Patents
Automatic grease filling system and method for roller Download PDFInfo
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- CN112145946B CN112145946B CN202011336432.1A CN202011336432A CN112145946B CN 112145946 B CN112145946 B CN 112145946B CN 202011336432 A CN202011336432 A CN 202011336432A CN 112145946 B CN112145946 B CN 112145946B
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- 239000004519 grease Substances 0.000 title claims abstract description 62
- 238000000034 method Methods 0.000 title claims description 12
- 238000002347 injection Methods 0.000 claims abstract description 66
- 239000007924 injection Substances 0.000 claims abstract description 66
- 238000012806 monitoring device Methods 0.000 claims abstract description 47
- 238000001514 detection method Methods 0.000 claims abstract description 30
- 230000005540 biological transmission Effects 0.000 claims abstract description 29
- 238000003860 storage Methods 0.000 claims abstract description 18
- 230000002159 abnormal effect Effects 0.000 claims abstract description 13
- 238000001228 spectrum Methods 0.000 claims description 9
- 230000003287 optical effect Effects 0.000 claims description 8
- 239000013307 optical fiber Substances 0.000 claims description 5
- 239000000835 fiber Substances 0.000 claims description 3
- 230000009286 beneficial effect Effects 0.000 abstract description 2
- 238000005457 optimization Methods 0.000 abstract 1
- 239000003921 oil Substances 0.000 description 141
- 230000001050 lubricating effect Effects 0.000 description 13
- 238000005299 abrasion Methods 0.000 description 4
- 238000000605 extraction Methods 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000004804 winding Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 3
- 239000000945 filler Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000013589 supplement Substances 0.000 description 2
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 229920001973 fluoroelastomer Polymers 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000010687 lubricating oil Substances 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000009897 systematic effect Effects 0.000 description 1
- 238000012549 training Methods 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N11/00—Arrangements for supplying grease from a stationary reservoir or the equivalent in or on the machine or member to be lubricated; Grease cups
- F16N11/08—Arrangements for supplying grease from a stationary reservoir or the equivalent in or on the machine or member to be lubricated; Grease cups with mechanical drive, other than directly by springs or weights
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N29/00—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N29/00—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems
- F16N29/02—Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems for influencing the supply of lubricant
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N37/00—Equipment for transferring lubricant from one container to another
- F16N37/003—Equipment for transferring lubricant from one container to another for filling bearings
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
- G08B21/18—Status alarms
- G08B21/24—Reminder alarms, e.g. anti-loss alarms
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/01—Protocols
- H04L67/02—Protocols based on web technology, e.g. hypertext transfer protocol [HTTP]
- H04L67/025—Protocols based on web technology, e.g. hypertext transfer protocol [HTTP] for remote control or remote monitoring of applications
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/01—Protocols
- H04L67/12—Protocols specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16N—LUBRICATING
- F16N37/00—Equipment for transferring lubricant from one container to another
- F16N2037/006—Filling
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Abstract
The invention relates to the technical field of transmission, and provides an automatic grease filling system for a roller, which comprises: the device comprises a detection device, an automatic oiling device, a detection main body, an online monitoring device and a data transmission device; automatic oiling device includes: the oil storage device, the oil pump and the oil injection pipeline; the detection main body includes: the oil injection device comprises a main shaft, a bearing, an outer bearing cover and an inner bearing cover, wherein the main shaft is respectively provided with an axial oil inlet channel and a radial oil injection hole which are communicated with each other, and the oil inlet channel is communicated with an oil injection pipeline; the detection device includes: a vibration sensor; the online monitoring device stores the equipment data and the historical oiling data of the roller and determines the oiling amount according to the abnormal values of the bearing service time and the frequency. The invention monitors the working state of the roller bearing on line, and automatically and accurately injects oil to the roller bearing through reasonable calculation and data optimization according to the actual requirement of the roller, thereby improving the oil injection efficiency and being beneficial to prolonging the service life of the roller bearing.
Description
Technical Field
The invention relates to the technical field of transmission, in particular to a system and a method for automatically filling grease into a roller.
Background
The permanent magnet roller has the advantages of simple mechanism, reliable operation, less loss, high efficiency, direct drive control and the like, is particularly suitable for application occasions with low speed and large torque, and is widely applied to industries such as petroleum, mining, metallurgy and steel rolling. After the outer rotor electric roller works for a period of time, lubricating oil needs to be filled into the bearing with the supporting function to reduce friction and prolong the service life of the bearing.
The permanent magnet roller is an outer rotor motor, is always in a rotating working state in the application of the belt conveyor, reduces the abrasion of a bearing in order to reduce the friction of the bearing of the permanent magnet roller, and needs to add lubricating grease to the bearing. The manual oil filling of current oiling mode needs regularly quantitative, can't effective accurate judge whether the lubricating grease of bearing lacks, consequently refuels time and volume of adding oil and can't arrange according to the actual need of bearing, refuels the effect and also can't predict.
Disclosure of Invention
The invention provides a roller automatic grease filling system and a method for solving the problems, wherein the system comprises an automatic grease filling device for automatically filling grease for a bearing and a detection device for detecting working parameters of the bearing, and the roller automatic grease filling system further comprises: the automatic oiling device comprises a detection main body, an online monitoring device and a data transmission device, wherein the detection main body is connected with the detection device and the automatic oiling device;
automatic oiling device includes: the oil storage device, the oil pump, the oil injection pipeline and the controller;
the detection main body includes: the main shaft is sleeved on a bearing of the main shaft, and an outer bearing cover and an inner bearing cover which are assembled on the main shaft at two sides of the bearing, and the main shaft is respectively provided with an axial oil inlet channel and a radial oil injection hole which are communicated with each other, wherein the oil inlet channel is communicated with the oil injection pipeline; when the oil is short of oil, the oil pump pumps out the grease in the oil storage device quantitatively, the grease is conveyed to the oil inlet channel along the axial direction of the main shaft through the oil injection pipeline, and after the grease reaches the position of the bearing, a radial oil injection hole reaching the bearing is formed in the main shaft at the position, so that the bearing is injected with oil.
The detection device includes: the vibration sensor is arranged at the end part of the main shaft close to the bearing or on the fixed seat; the vibration sensor detects the amplitude data of the bearing and transmits the amplitude data to the data acquisition unit;
the online monitoring device stores equipment data, historical oiling data, real-time amplitude data, bearing service duration data and frequency abnormal values of the roller to determine oiling amount; and the online monitoring device transmits the oil filling amount data to the controller through the data transmission device so as to control the oil filling amount of the oil storage device.
The frequency data is processed through FFT to obtain a vibration frequency spectrum, and the frequency point f where the abnormal amplitude is located in the vibration frequency spectrumeThe rotation speed omega acquired by the rotation speed sensor satisfies the functional relation of the formula (1), or the roller frequency f and the rated rotation speed
If the functional relation of the formula (2) is met, judging that oil needs to be injected, otherwise, judging that the oil needs to be injected as running environment noise;
formula (1)
Formula (2)
Wherein omega is the rotating speed collected by the rotating speed sensor,
at a rated rotational speed, feIs the frequency point of abnormal amplitude in the vibration frequency spectrum, f is the drum frequency,
is a coefficient ranging from 0 to 1, n is a positive integer greater than 0,
is the drum frequency average.
According to the invention, the vibration model is associated with the oil injection amount through the online monitoring device, and oil injection is carried out according to the actual requirement of the bearing, so that accurate and automatic oil injection is realized, the complexity of manual oil injection is avoided, and the unsafe factor of manual oil injection is avoided.
Preferably, the online monitoring device further comprises an oil injection pre-reminding unit, and the oil injection pre-reminding unit performs oil injection pre-reminding based on the stored real-time amplitude data and amplitude threshold of the bearing. Real-time amplitude data are output through a real-time vibration model of the bearing, the real-time vibration data and frequency data are compared with historical oil injection data, and the oil quantity surplus of the bearing and the time of the bearing in the next oil injection can be judged in advance, so that the setting is reminded.
Preferably, the online monitoring device further comprises an oil injection feedback unit, and the data transmission device transmits the amplitude data of the bearing after oil injection to the oil injection feedback unit. After the oiling is finished, whether the bearing meets the normal working state or not can be judged through each vibration index in the vibration model, and therefore the oiling effect is fed back.
Preferably, the historical oiling data comprises: historical oiling time, historical oiling duration, historical oiling speed and historical oiling amount.
Preferably, the vibration sensor is internally provided with a temperature compensation device, and the temperature compensation device converts the ambient temperature into first amplitude compensation;
preferably, the vibration sensor is internally provided with a noise compensation device, and the noise compensation device converts the environmental noise into second amplitude compensation;
preferably, a humidity compensation device is arranged in the vibration sensor, and the humidity compensation device converts the ambient humidity into third amplitude compensation;
because the vibration of bearing receives external environment influence great, consequently take into account ambient temperature, the noise of material transport and mechanical motion's noise, the humidity factor of environment, through the inside compensation function's that carries out temperature, noise and humidity of vibration sensor settlement in order to reduce the influence of above-mentioned factor.
Preferably, the data transmission device is designed for transmitting optical signals or radio signals.
Preferably, the data transmission device is an optical fiber device; the optical fiber equipment converts the oil filling quantity optical signal determined by the online monitoring device into an oil filling quantity electric signal to be transmitted to the controller, and the oil filling quantity electric signal is transmitted to the automatic oil filling device through the controller.
Preferably, the oil storage device is provided with an oil quantity prompting sensor to prompt the residual oil quantity of the oil storage device, so that timely supplement is facilitated, and the situation that lubricating grease cannot be timely provided for the bearing due to the shortage of the oil quantity of the oil storage device is avoided.
Preferably, be equipped with automatic oil extraction valve on the outer bearing cap, when the bearing oiling surpassed actual need, the automatic oil extraction valve on the outer bearing cap can in time get rid of the grease, avoids inside the grease gets into the organism, influences the winding insulation of stator.
Preferably, a framework oil seal is arranged between the outer bearing cover and the inner bearing cover, and particularly, an outer framework oil seal is arranged between the outer bearing cover and the bearing outer ring to prevent lubricating grease in the bearing from leaking and effectively prevent an outer ash layer from entering the bearing; an inner side framework oil seal is arranged between the inner bearing cover and the bearing inner ring to prevent lubricating grease from entering the interior of the equipment body and affecting the insulation of the stator winding.
Based on the automatic grease filling system for the roller, the invention also provides an automatic grease filling method for the system, which comprises the following steps:
the vibration sensor detects real-time amplitude data of the bearing and transmits the real-time amplitude data to the online monitoring device through the data acquisition unit;
comparing the real-time amplitude data to an amplitude threshold calculated by the online monitoring device;
if the real-time amplitude data is smaller than the amplitude threshold value, the online monitoring device stores the real-time amplitude data for multiple times to perform oil injection pre-reminding;
and if the real-time amplitude data is larger than the amplitude threshold value, the online monitoring device transmits an oil injection amount signal to the automatic oil injection device through the data transmission device.
The invention has the beneficial effects that:
(1) according to the automatic oiling device, the online monitoring device is used for controlling the automatic oiling device to perform oiling according to needs, so that automatic and accurate oiling is realized, and complicated and unsafe factors of manual operation are avoided.
(2) The invention can lubricate the bearing according to the requirement, avoid the abrasion of the bearing caused by lack of lubricating grease and prolong the service life of the bearing.
(3) The online monitoring device can be carried remotely, and adjustment operation is carried out on mobile terminals such as mobile phones based on cloud computing of the Internet of things, so that the online monitoring device is convenient and quick.
Drawings
FIG. 1 is a schematic view of an automatic grease filling system for a roller according to embodiments 1 and 2 of the present invention;
fig. 2 is a schematic view of the spindle provided with circumferential grooves and axial grooves in embodiment 2 of the present invention.
Detailed Description
Specific embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. While specific embodiments of the invention are shown in the drawings, it should be understood that the invention may be embodied in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
It should be noted that certain terms are used throughout the description and claims to refer to particular components. As one skilled in the art will appreciate, various names may be used to refer to a component. This specification and claims do not intend to distinguish between components that differ in name but not function. In the following description and in the claims, the terms "include" and "comprise" are used in an open-ended fashion, and thus should be interpreted to mean "include, but not limited to. The description which follows is a preferred embodiment of the invention, but is made for the purpose of illustrating the general principles of the invention and not for the purpose of limiting the scope of the invention. The scope of the present invention is defined by the appended claims.
Embodiment 1 this embodiment provides an automatic grease filling system for a roller.
As shown in fig. 1, the system comprises an automatic oiling device for automatically filling the bearing with grease and a detection device for detecting the working parameters of the bearing, and the automatic roller grease filling system further comprises: the automatic oiling device comprises a detection main body, an online monitoring device and a data transmission device 14, wherein the detection main body is connected with the detection device and the automatic oiling device;
automatic oiling device includes: the oil storage device 1, the oil pump 2, the oil filling pipeline 3 and the controller 19;
the detection main body includes: the main shaft 4 is sleeved on a bearing 5 of the main shaft, and an outer bearing cover 6 and an inner bearing cover 7 which are assembled on the main shaft 4 at two sides of the bearing 5, the main shaft 4 is respectively provided with an axial oil inlet channel 8 and a radial oil injection hole 9 which are communicated, wherein the oil inlet channel 8 is communicated with the oil injection channel 3;
the detection device comprises: the device comprises a data acquisition unit 11 and a vibration sensor 10, wherein the vibration sensor 10 is arranged on the end part of a main shaft 4 close to a bearing 5 or a fixed seat 20 at the end part of the main shaft 4; the vibration sensor 10 detects the amplitude data of the bearing 5 and transmits the amplitude data to the data collector 11;
the online monitoring device 15 stores the equipment data, the historical oiling data, the real-time amplitude data, the bearing service duration data and the frequency abnormal value of the roller to determine the oiling amount; the on-line monitoring device 15 transmits the data of the oil filling amount to the controller 19 through the data transmission device 14 to control the oil filling amount of the oil storage device 1.
The online monitoring device 15 further comprises an oil injection feedback unit, and the data transmission device 14 transmits the amplitude data of the bearing after oil injection to the oil injection feedback unit.
A temperature compensation device is arranged in the vibration sensor 10, and converts the ambient temperature into first amplitude compensation;
a noise compensation device is arranged in the vibration sensor 10, and converts the environmental noise into second amplitude compensation;
a humidity compensation device is arranged in the vibration sensor 10 and converts the environment humidity into third amplitude compensation;
the data transmission means 14 are designed for transmitting optical signals or radio signals.
In a preferred embodiment, the data transmission device 14 is a fiber optic device; the optical fiber equipment converts the optical oil injection amount signal determined by the online monitoring device into an electric oil injection amount signal and transmits the electric oil injection amount signal to the controller 19, and the electric oil injection amount signal is transmitted to the automatic oil injection device through the controller 19.
The oil storage device 1 is provided with an oil quantity prompt sensor, the outer bearing cover 6 is provided with an automatic oil discharge valve, and a framework oil seal 13 is arranged between the outer bearing cover 6 and the inner bearing cover 7.
This embodiment carries out the oiling through on-line monitoring device through being related vibration model and oiling volume according to the actual need of bearing, has realized accurate automatic oiling, has removed the loaded down with trivial details of artifical oiling from, has avoided the unsafe factor of artifical oiling.
Example 2 this example provides an alternative roller automatic grease filling system.
As shown in fig. 1, the system comprises an automatic oiling device for automatically filling the bearing with grease and a detection device for detecting the working parameters of the bearing, and the automatic roller grease filling system further comprises: the detection main body is connected with the detection device and the automatic oiling device, the online monitoring device and the data transmission device 14 is used for data transmission among the online monitoring device, the automatic lubricating device and the detection device;
automatic oiling device includes: the oil storage device 1, the oil pump 2, the oil filling pipeline 3 and the controller 19;
the detection main body includes: the main shaft 4, the bearing 5 of cover locating the main shaft, assemble outer bearing cap 6 and interior bearing cap 7 on the main shaft 4 of bearing 5 both sides, axial oil feed passageway 8 is seted up to one end on the main shaft 4, sets up radial oil filler point 9 respectively at the both ends of main shaft 4, and oil feed passageway 8 communicates with the radial oil filler point 9 at both ends, has realized giving the bearing oiling simultaneously. When the oil is short of oil, the oil pump 2 pumps out the grease in the oil storage device 1 quantitatively, the grease is conveyed to the oil inlet channel 8 along the axial direction of the main shaft through the oil injection pipeline 3, and after the grease reaches the position of the bearing 5, a radial oil injection hole 9 reaching the bearing 5 is formed in the main shaft 4 at the position, so that the bearing 5 is injected with oil. As shown in fig. 2, a circumferential groove 16 is circumferentially turned along the radial oil injection hole 9 on the main shaft 4, a plurality of axial grooves which are circumferentially distributed are respectively milled along the axial direction of the main shaft beside the circumferential groove 16 towards the inner direction of the shaft, the depth of the axial groove is smaller than that of the circumferential groove 16, and meanwhile, the axial groove is provided with a length exceeding a positioning step so as to meet the requirement that the circumferential groove 16 is filled at the two ends of the main shaft 4 firstly when oil is injected, and after the circumferential groove 16 is filled, the axial groove slowly flows to the plurality of axial grooves which are uniformly distributed, then overflows from the axial groove and uniformly and slowly flows into the bearing 5, so that uneven oil injection.
As an optimal mode, two ends of the main shaft 4 are provided with positioning steps, the bearings 5 are positioned through the positioning steps, two ends of the main shaft 4 are respectively provided with an axial oil inlet channel 8, and radial oil injection holes 9 are respectively formed to respectively inject oil to the bearings 5 at the two ends.
The detection device comprises: the device comprises a data acquisition unit 11 and a vibration sensor 10, wherein the vibration sensor 10 is arranged on a fixed seat 20 at the end part of a main shaft 4 close to a bearing 5; the vibration sensor 10 detects the amplitude data of the bearing 5 and transmits the amplitude data to the data collector 11;
the online monitoring device 15 stores the equipment data, the historical oiling data, the real-time amplitude data, the bearing service duration data and the frequency abnormal value of the roller to determine the oiling amount; the on-line monitoring device 15 transmits the data of the oil filling amount to the controller 19 through the data transmission device 14 to control the oil filling amount of the oil storage device 1.
The vibration of the bearing 5 drives the main shaft 4 near the bearing to vibrate synchronously, so the aim of measuring the vibration amplitude of the bearing 5 is achieved by indirectly measuring the vibration of the main shaft 4, the fixing seat 20 is sleeved at the end part of the main shaft 4 and used for fixing the main shaft 4, and the vibration sensor 10 is arranged at the end part of the main shaft 4 close to the bearing or on the fixing seat 20 and can measure the vibration amplitude of the bearing. The reasons for the vibration of the bearing include: friction between the bearing and the main shaft, depression and abrasive particles in the manufacturing process of the bearing, collision and scratch in the use process of the bearing, unclean lubricating grease and the like. The vibration model of the bearing is related to the waveform of the vibration of the bearing and the number of rollers for conveying materials, wherein the waveform indexes of the vibration of the bearing comprise a peak value, a root mean square value, a form factor, a probability density and a kurtosis coefficient. The peak value reflects the maximum value of the amplitude at a certain moment, and the root mean square value is the average of the amplitude and the time, so that the method is particularly suitable for the amplitude value of the wear type irregular vibration and the like which slowly changes along with the time. The form factor is defined as the ratio of the peak value to the average amplitude value, and when the form factor value is too large, the wear is indicated; the probability density curve of the amplitude of the faultless rolling bearing is a typical normal distribution curve; and once a fault occurs, the probability density curve may be skewed or scattered. The bearing has the advantages that due to factors such as abrasion and fatigue, the bearing amplitude is increased, vibration harmonics are increased, high-density regions are increased, low-density regions on two sides are expanded outwards, and the kurtosis coefficient is effectively used as a diagnostic characteristic quantity. The vibration indexes are different for different models and types of equipment. This embodiment is through the vibration model who sets up bearing 5, and above-mentioned vibration index is long along with the bearing length of use when having considered comprehensively that bearing 5 lacks the grease to constantly optimize the vibration model of training bearing 5, combine historical oiling data to revise the oiling volume, and output present oiling volume data to automatic oiling device's controller 19.
The online monitoring device 15 further comprises an oil injection pre-reminding unit, and the oil injection pre-reminding unit performs oil injection pre-reminding based on the stored amplitude data and amplitude threshold of the bearing. Real-time amplitude data are output through a real-time vibration model of the bearing, the real-time vibration data are compared with historical oil injection data, and the oil quantity surplus of the bearing and the time of the bearing in the next oil injection can be judged in advance, so that the setting is reminded.
The on-line monitoring device 15 further comprises an oil injection feedback unit, and the data transmission device transmits the amplitude data of the bearing after oil injection to the oil injection feedback unit. After the oiling is finished, whether the bearing meets the normal working state or not can be judged through each vibration index in the vibration model, and therefore the oiling effect is fed back.
The historical oiling data includes: historical oiling time, historical oiling duration, historical oiling speed and historical oiling amount.
The vibration sensor 10 is internally provided with a temperature compensation device which converts the ambient temperature into a first amplitude compensation;
the vibration sensor 10 is internally provided with a noise compensation device which converts the environmental noise into a second amplitude compensation;
a humidity compensation device is arranged in the vibration sensor 10, and the humidity compensation device converts the ambient humidity into third amplitude compensation;
because the vibration of bearing receives external environment influence great, consequently take into account ambient temperature, the noise of material transport and mechanical motion's noise, the humidity factor of environment, through the inside compensation function's that carries out temperature, noise and humidity of vibration sensor settlement in order to reduce the influence of above-mentioned factor.
The data transmission means 14 are designed for transmitting optical signals or radio signals.
In a preferred embodiment, the data transmission device 14 is a fiber optic device; the optical fiber equipment converts the optical oil injection amount signal determined by the online monitoring device into an electric oil injection amount signal and transmits the electric oil injection amount signal to the controller 19, and the electric oil injection amount signal is transmitted to the automatic oil injection device through the controller 19.
The oil storage device 1 is provided with an oil quantity prompt sensor to prompt the residual oil quantity of the oil storage device, so that timely supplement is facilitated, and the problem that lubricating grease cannot be timely provided for the bearing due to the shortage of the oil quantity of the oil storage device is avoided.
Be equipped with automatic oil extraction valve on the outer bearing cap 6, when 5 oiling of bearing surpassed actual need, the automatic oil extraction valve on the outer bearing cap 6 can in time get rid of the grease, avoids inside the grease gets into the organism, influences the winding insulation of stator. A framework oil seal 13 is arranged between the outer bearing cover 6 and the inner bearing cover 7, and particularly, an outer framework oil seal is arranged between the outer bearing cover 6 and the outer ring of the bearing 5 to prevent lubricating grease in the bearing 5 from leaking and effectively prevent an outer ash layer from entering the bearing; an inner side framework oil seal is arranged between the inner bearing cover 7 and the inner ring of the bearing 5 to prevent lubricating grease from entering the interior of the equipment body and affecting the insulation of the stator winding.
As preferred mode, the material of outside skeleton oil blanket is fluororubber, outside skeleton oil blanket is double sealing lip structure, double sealing lip is outside vice lip and inside lip respectively, outside skeleton oil blanket inner circle is equipped with the recess, place in the recess and use the spring coil with locking, the locking spring coil is used for preventing outside skeleton oil blanket inner circle pine and reduces the leakproofness, the outer lane of outside skeleton oil blanket closely cooperates with the mounting hole of outer bearing cap, the inner circle and the axle of outside skeleton oil blanket closely cooperate, the outside skeleton oil blanket outside vice lip that outer bearing cap set up is used for preventing dust, the inside lip is used for sealed lubricating grease, prevent that the grease from flowing out, bearing lubrication inefficacy.
In a preferred embodiment, there is provided a systematic method of automatic grease filling, the method comprising:
the vibration sensor 10 detects real-time amplitude data of the bearing 5 and transmits the real-time amplitude data to the online monitoring device 15 through the data acquisition unit 11;
comparing the real-time amplitude data with an amplitude threshold value calculated by the online monitoring device 15;
if the real-time amplitude data is smaller than the amplitude threshold value, the online monitoring device stores the real-time amplitude data for multiple times to perform oil injection pre-reminding;
if the real-time amplitude data is larger than the amplitude threshold value, the online monitoring device transmits the oil filling quantity signal to the automatic oil filling device through the data transmission device 14.
The automatic grease filling system further comprises a collecting roller rotating speed
The rotational speed sensor of (1). And performing FFT processing on the frequency acquired by the vibration sensor to obtain a vibration frequency spectrum. If the frequency point f of abnormal amplitude in the vibration frequency spectrumeThe rotating speed collected by the rotating speed sensor
The functional relation of formula (1) is satisfied, or the drum frequency f and the rated rotation speed
And (3) satisfying the functional relation of the formula (2), judging that oil needs to be injected, and sending oil injection reminding, otherwise, judging as the noise of the operating environment.
Wherein,
is the rotating speed collected by the rotating speed sensor,
at a rated rotational speed, feIs the frequency point of abnormal amplitude in the vibration frequency spectrum, f is the drum frequency,
is a coefficient ranging from 0 to 1, n is a positive integer greater than 0,
is the drum frequency average.
According to the algorithm, on one hand, abnormal frequency caused by non-roller reasons, such as vibration caused by falling stones in the transportation process and the like, is eliminated, on the other hand, the abnormal frequency caused by the roller reasons is effectively judged, and oil injection reminding is timely sent out.
In the embodiment, the automatic oil injection device is controlled by the online monitoring device to inject oil as required, so that automatic and accurate oil injection is realized, and the complex and unsafe factors of manual operation are avoided. The bearing is lubricated as required, so that the abrasion of the bearing caused by lack of lubricating grease is avoided, and the service life of the bearing is prolonged. The online monitoring device of the embodiment can be remotely carried, and the cloud computing based on the Internet of things can be adjusted and operated at mobile terminals such as mobile phones, and is convenient and fast.
The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that although the present specification describes the embodiments, the above-mentioned embodiments are exemplary and not intended to limit the scope of the present invention, and any changes, modifications, substitutions and alterations made by those skilled in the art without departing from the principle and spirit of the present invention shall be included in the scope of the present invention.
Claims (12)
1. An automatic grease filling system for a roller comprises an automatic grease filling device for automatically filling grease for a bearing and a detection device for detecting working parameters of the bearing,
the automatic roller grease filling system further comprises: the detection device comprises a detection main body, an online monitoring device and a data transmission device (14), wherein the detection main body is connected with the detection device and the automatic oiling device, and the data transmission device is used for carrying out data transmission among the online monitoring device, the automatic oiling device and the detection device;
automatic oiling device includes: the device comprises an oil storage device (1), an oil pump (2), an oil injection pipeline (3) and a controller (19);
the detection main body includes: the main shaft (4) is sleeved on a bearing (5) of the main shaft, and an outer bearing cover (6) and an inner bearing cover (7) which are assembled on the main shaft (4) at two sides of the bearing (5), the main shaft (4) is respectively provided with an axial oil inlet channel (8) and a radial oil injection hole (9) which are communicated with each other, wherein the oil inlet channel (8) is communicated with the oil injection pipeline (3);
the detection device includes: the vibration sensor (10) is arranged at the end part of the main shaft (4) close to the bearing (5) or on the fixed seat (20); the vibration sensor (10) detects the amplitude data and the frequency data of the bearing and transmits the amplitude data and the frequency data to the data acquisition unit (11);
the online monitoring device (15) stores the equipment data, the historical oiling data, the real-time amplitude data, the bearing service duration data and the frequency abnormal value of the roller and determines the oiling amount; the online monitoring device (15) transmits the oil filling amount data to the controller (19) through the data transmission device (14) so as to control the oil filling amount of the oil storage device (1);
the frequency data is processed through FFT to obtain a vibration frequency spectrum, and the frequency point f where the abnormal amplitude is located in the vibration frequency spectrumeThe rotation speed omega acquired by the rotation speed sensor satisfies the functional relation of the formula (1), or the roller frequency f and the rated rotation speed
If the functional relation of the formula (2) is met, judging that oil needs to be injected, otherwise, judging that the oil needs to be injected as running environment noise;
formula (1)
Formula (2)
Wherein, omega is the rotating speed collected by the rotating speed sensor, and is the rated rotating speed, feIs the frequency point of abnormal amplitude in the vibration frequency spectrum, f is the drum frequency and is a coefficient ranging from 0 to 1, n is a positive integer greater than 0,
is the drum frequency average;
the online monitoring device (15) is also provided with a vibration model of the bearing (5), the vibration model of the bearing (5) is optimized and trained based on the change of bearing vibration indexes along with the service duration of the bearing when the bearing (5) is lack of grease, and the vibration model corrects the oiling amount by combining historical oiling data;
the online monitoring device (15) further comprises an oil injection pre-reminding unit, and the oil injection pre-reminding unit performs oil injection pre-reminding based on the stored real-time amplitude data and amplitude threshold value of the bearing.
2. The automatic roller grease filling system according to claim 1, wherein the online monitoring device (15) further comprises an oiling feedback unit, and the data transmission device (14) transmits the oiled bearing amplitude data to the oiling feedback unit.
3. The automatic roller grease filling system of claim 1 wherein the historical grease filling data comprises: historical oiling time, historical oiling duration, historical oiling speed and historical oiling amount.
4. Automatic roller grease filling system according to claim 1, characterized in that the vibration sensor (10) incorporates a temperature compensation device which converts the ambient temperature into a first amplitude compensation.
5. Automatic roller grease filling system according to claim 1, characterized in that the vibration sensor (10) incorporates a noise compensation device which converts ambient noise into a second amplitude compensation.
6. The system for automatic grease filling of a roller according to claim 1, characterized in that the vibration sensor (10) incorporates a humidity compensation device which converts the ambient humidity into a third amplitude compensation.
7. Automatic roller grease filling system according to claim 1, characterized in that the data transmission means (14) are designed for transmitting optical signals or radio signals.
8. The automatic roller grease filling system according to claim 7, characterized in that the data transmission means (14) is a fiber optic device; the optical fiber equipment converts the oil filling quantity optical signal determined by the online monitoring device into an oil filling quantity electric signal to be transmitted to the controller (19), and the oil filling quantity electric signal is transmitted to the automatic oil filling device through the controller (19).
9. Automatic roller grease filling system according to claim 1, characterized in that the reservoir (1) is provided with a sensor for indicating the amount of grease.
10. Automatic roller grease filling system according to claim 1, characterized in that the outer bearing cap (6) is provided with an automatic oil drain valve.
11. An automatic grease filling system for a roller according to claim 1, characterized in that a skeleton oil seal (13) is provided between the outer bearing cover (6) and the inner bearing cover (7).
12. An automatic grease filling method using the system according to any one of claims 1 to 11, wherein the automatic grease filling method comprises:
the vibration sensor (10) detects real-time amplitude data of the bearing (5) and transmits the real-time amplitude data to the online monitoring device (15) through the data acquisition unit (11);
comparing the real-time amplitude data with an amplitude threshold value calculated by the online monitoring device (15);
if the real-time amplitude data is smaller than the amplitude threshold value, the online monitoring device stores the real-time amplitude data for multiple times to perform oil injection pre-reminding;
and if the real-time amplitude data is larger than the amplitude threshold value, the online monitoring device transmits the oil filling quantity signal to the automatic oil filling device through the data transmission device (14).
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| CN202011336432.1A CN112145946B (en) | 2020-11-25 | 2020-11-25 | Automatic grease filling system and method for roller |
| PCT/CN2021/131114 WO2022111350A1 (en) | 2020-11-25 | 2021-11-17 | Roller automatic grease filling system and method |
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| CN202011336432.1A CN112145946B (en) | 2020-11-25 | 2020-11-25 | Automatic grease filling system and method for roller |
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| CN112145946B (en) * | 2020-11-25 | 2021-03-30 | 江苏嘉轩智能工业科技股份有限公司 | Automatic grease filling system and method for roller |
| CN113294678B (en) * | 2021-05-29 | 2022-04-01 | 河南工学院 | Regular automatic maintenance device of gantry crane |
| CN115479203B (en) * | 2022-09-22 | 2023-07-18 | 常州富兴机电有限公司 | Oiling tool |
| CN116972320B (en) * | 2023-09-21 | 2024-01-12 | 青岛埃恩斯信息技术科技有限公司 | Vibration detection-based lubrication control method for rotary equipment |
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