U.S. patent application number 11/902181 was filed with the patent office on 2011-10-20 for automatic grease dispensing monitoring and alarm system.
Invention is credited to Shih-Kuei Lin.
Application Number | 20110253481 11/902181 |
Document ID | / |
Family ID | 44787353 |
Filed Date | 2011-10-20 |
United States Patent
Application |
20110253481 |
Kind Code |
A1 |
Lin; Shih-Kuei |
October 20, 2011 |
Automatic grease dispensing monitoring and alarm system
Abstract
An automatic grease dispensing monitoring and alarm system using
a control unit in each automatic grease dispenser to provide
message to a center monitoring control and alarm system wirelessly,
achieving wireless remote lubrication control, abnormality alarm,
and auto grease-dispensing functions. Each automatic grease
dispenser comprises a driving mechanism for driving a piston to
dispense the lubricating grease, a microprocessor-based control
unit for the setting of the lubricating cycle and for checking the
grease dispensing amount subject to the detection of the rate of
turn of the driving mechanism through a sensor and a black and
white reflective plate.
Inventors: |
Lin; Shih-Kuei; (Taoyuan
City, TW) |
Family ID: |
44787353 |
Appl. No.: |
11/902181 |
Filed: |
September 19, 2007 |
Current U.S.
Class: |
184/108 |
Current CPC
Class: |
F16N 2230/02 20130101;
F16N 2230/22 20130101; F16N 11/08 20130101; F16N 2250/16 20130101;
F16N 2270/20 20130101; F16N 29/00 20130101 |
Class at
Publication: |
184/108 |
International
Class: |
F01M 11/10 20060101
F01M011/10 |
Claims
1. An automatic grease dispensing monitoring and alarm system
comprising: a plurality of automatic grease dispensers installed in
mechanical parts at different locations in a factory, said
automatic grease dispensers each comprising a housing covered with
a top cap, a grease container mounted inside said housing and
connected to the associating mechanical part and holding a
lubricating grease, a piston mounted in said grease container and
adapted to force the lubricating grease out of said grease
container into the associating mechanical part, a propelling device
controllable to move said piston, a driving mechanism adapted to
drive said propelling device to move said piston, said driving
mechanism comprising a motor and a speed reducing gear set coupled
between said motor and said propelling device, a control unit
adapted to control operation of said driving mechanism, said
control unit comprising a microprocessor, a sensor and a
black-and-white reflection signal plate adapted to detect the rate
of turn of said driving mechanism and to feed back detected data to
said microprocessor for reading, an indicator lamp adapted to give
a visual warning signal when the reading of said microprocessor is
out of a normal range, a battery mounted in said top cap and
electrically connected to said control unit and said driving
mechanism to provide the necessary working voltage, and a
transmitter electrically connected to said microprocessor for data
transmission wirelessly to a center monitoring control and alarm
system; and a center monitoring control and alarm system disposed
in communication with the transmitters of said automatic grease
dispensers wirelessly and adapted to calculate and record the
amount of the lubricating grease dispensed by each of said
automatic grease dispensers, to set and calculate the lubricating
cycle of each of said automatic grease dispenser, to record the
routine check and maintenance records of each of said automatic
grease dispensers, and to provide data inquiry and message updating
functions, said center monitoring control and alarm system giving
an alarm signal upon interruption of the connection of one of said
automatic grease dispensers and indicate the location and data of
the automatic grease dispenser that is in trouble.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a lubricating grease
dispensing system and more particularly, to an automatic grease
dispensing monitoring and alarm system, which comprises a plurality
of automatic grease dispensers installed in different mechanical
parts at different locations in a factory, and a center monitoring
control and alarm system connected to the automatic grease
dispensers wirelessly and adapted to control lubricating operation
of the automatic grease dispensers, to monitor and record their
lubrication data, or to give an alarm signal if any automatic
grease dispenser fails.
[0003] 2. Description of the Related Art
[0004] Conventionally, the lubricating points of industrial
machinery systems are lubricated point by point with a manual
grease dispensing gun, power grease dispensing gun, or pneumatic
grease dispensing gun by labor. These lubricating points are also
regularly checked and maintained point by point. The grease content
of the bearing at each lubricating point can be measured. However,
because the number of lubricating points of an industrial machinery
system is numerous and because each lubricating point has a
different operation condition and requirement, it is difficult to
control the lubricating grease dispensing amount for each
lubricating point or to estimate the supplying cycle (maintenance
interval) of each lubricating point. The lubricating grease
dispensing amount for each lubricating point is usually determined
subject to the skill workmen's experience. Maintaining lubricating
points by means of experience cannot is not the best way because it
cannot eliminate the problem of excessive applied amount of
lubricating grease that may cause damage of the axle seal, and the
problem of grease leakage. More particularly, a skill workman
cannot accurate check the amount of lubricating grease in an
enclosed lubrication point (such as the axle bearing of a motor) by
experience.
[0005] An excessive amount of lubricating grease will lower the
heat dissipation efficiency of the axle bearing or mechanical part,
causing damage to the axle seal and the axle bearing or mechanical
part. Insufficient amount of lubricating grease cannot provide the
necessary lubrication, and the axle bearing or mechanical part will
wear soon. Therefore, conventional lubricating point maintaining
methods require much labor and time and may affect normal
production. There are many commercial lubricating grease dispensers
that use spring means or pneumatic force to dispense lubricating
grease. However, these conventional lubricating grease dispensers
are not satisfactory in function. The mechanics must regularly
check the functioning of the lubricating grease dispensers. When
one grease dispenser failed, the workman or mechanic cannot know
the condition to take the necessary steps before damage occurs.
[0006] Further, a conventional automatic grease dispenser can
automatically dispense lubricating grease. However, it calculates
the grease output amount subject to the number of displacement
actions of the plunger. This measurement has a low accuracy.
Because lubricating grease is a mixture of base oil and soap
thickener. These two substances have different density and
different physical properties. They cause different physical
changes when the pressure or temperature is changed. Except the
change of flowability (viscosity) toward a relatively thickener and
hardener status, the grease dispensing amount will also be affected
and changed. The workman cannot judge whether or not the grease
dispensing amount has been reduced due to a change of the physical
properties of the lubricating grease. In case the grease dispenser
is blocked and unable to function normally, the workman cannot find
the problem immediately.
[0007] Therefore, it is desirable to provide an automatic grease
dispensing monitoring and alarm system that eliminates the
aforesaid problems.
SUMMARY OF THE INVENTION
[0008] The present invention has been accomplished under the
circumstances in view. An automatic grease dispensing monitoring
and alarm system provided by the present invention allows setting
of different lubricating cycle for controlling the operation of
multiple automatic grease dispensers at different locations
individually. Each automatic grease dispenser comprises a control
unit that controls a driving mechanism to move a piston, forcing a
propelling device to propel lubricating grease out of a grease
container into the axle bearing, i.e., lubricating grease is stored
in a common space defined between the bearing and the grease
container below the piston and automatically supplied to the axle
bearing subject to the principle of equalized pressure in one same
space. A sensor automatically detects the rate of turn of the
driving mechanism and provides the data to a control chip (MIC) for
reading. The data thus obtained is transmitted to a center
monitoring control and alarm system wirelessly. If the wireless
connection is interrupted, the center monitoring control and alarm
system immediately gives an alarm signal and indicates the location
and history data of the automatic grease dispenser in trouble,
enabling the workman to take the necessary steps soon.
[0009] In general, the automatic grease dispensing monitoring and
alarm system of the present invention has the following features
and benefits:
[0010] 1. The automatic grease dispensing monitoring and alarm
system allows setting of lubricating grease dispensing cycle for
each automatic grease dispenser so that the automatic grease
dispensers automatically lubricate the respective lubricating
points with a proper amount of lubricating grease; by means of the
operation of a motor and gear driving mechanism and the detection
of a sensor to detect the rate of turn of the motor and gear
driving mechanism and the data reading and compensation correction
operation of the control chip (MIC), lubricating points are
properly lubricated.
[0011] 2. The control unit of every automatic grease dispenser
controls the associating driving mechanism to move the associating
propelling device, achieving timing and quantitative grease
dispensing operation; the sensor of the control unit detects the
rate of turn of the associating driving mechanism and feeds the
detected data back to the microprocessor of the circuit board for
reading and calculation of a compensation value to correct the
supply of lubricating grease, thereby eliminating the affect of a
physical property change of the lubricating grease and assuring
stable output amount of the lubricating grease.
[0012] 3. When the driving mechanism is operated to move the
pressure board of the propelling device and a piston downwards, the
speed of the motor and the electric current applied to the motor of
the driving mechanism are measured for correction of grease
dispensing amount, avoiding interference of physical property
changes of the lubricating grease (flowability change due to change
of pressure or temperature), assuring stable supply of the
lubricating grease.
[0013] 4. In case of an output abnormality, malfunctioning or
operation interruption of either automatic grease dispenser or a
connection failure between either automatic grease dispenser and
the center monitoring control and alarm system, the center
monitoring control and alarm system immediately gives an alarm
signal and indicate the location and data of the automatic greater
dispenser in trouble so that the workman can take the necessary
steps immediately.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an elevational view of an automatic grease
dispenser of an automatic grease dispensing monitoring and alarm
system in accordance with the present invention.
[0015] FIG. 2 is an exploded view of the automatic grease dispenser
shown in FIG. 1.
[0016] FIG. 3 is a perspective view of a part of the present
invention, showing the positioning of the sensor and
black-and-white reflecting signal plate relative to the speed
reducing gear set.
[0017] FIG. 4 is an applied view of the present invention, showing
the automatic grease dispenser installed in a bushing holder.
[0018] FIG. 5 is another applied view of the present invention,
showing the automatic grease dispenser installed in a bearing
block.
[0019] FIG. 6 is a schematic drawing showing a wireless control
arrangement of the present invention.
[0020] FIG. 7 is a circuit block diagram of the center monitoring
control and alarm system according to the present invention.
[0021] FIG. 8 is an operation flow chart of the center monitoring
control and alarm system according to the present invention.
[0022] FIG. 9 is a schematic drawing showing a wireless sensor
network constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIGS. 1-3, an automatic grease dispenser in
accordance with the present invention is shown comprised of a
housing 1, a holder frame 2, a driving mechanism 3, a control unit
4, a propelling device 5, and a grease container 6. The bottom side
of the body 11 of the housing 1 is an open side. The top side of
the body 11 is configured to accommodate a battery 43 of the
control unit 4. Further, a top cap 12 is threaded onto the top side
of the body 11 to hold down the battery 43.
[0024] The holder frame 2 is fixedly mounted in the body 11 of the
housing 1 to block the grease container 6 from parts disposed at
the top side of the holder frame 2, comprising a plurality of
upright supports 22, a top mount 21 affixed to the upright supports
22 at the top.
[0025] The driving mechanism 3 comprises a motor 31 fixedly mounted
on the top mount 21, a speed reducing gear set 32 installed in the
holder frame 2 below the top mount 21 and surrounded by the upright
supports 22 and coupled to the motor 31, and the aforesaid
propelling device 5. The propelling device 5 comprises a screw tube
51 coupled to the speed reducing gear set 32.
[0026] Referring to FIGS. 2 and 3 again, the control unit 4
comprises a circuit board 41, a sensor 42, the aforesaid battery
43, a black-and-white reflection signal plate 44, and a setting
switch 45. The black-and-white reflection signal plate 44 is
disposed above the speed reducing gear set 32 corresponding to the
sensor 42 and rotatable by the speed reducing gear set 32. During
rotation of the speed reducing gear set 32, the sensor 42 detects
the speed of the black-and-white reflection signal plate 44 subject
to cycling of on and off signals (black and white reflecting
signals). The sensor 42 feeds back the detected signal to the
circuit board 41 for calculating the dispensing amount of the
lubricating grease. The circuit board 41 comprises a LED (light
emitting diode) 411, which is inserted into (a through hole of) the
body 11 of the housing 1 and controlled to provide a visual warning
signal.
[0027] The aforesaid propelling device 5 is comprised of the
aforesaid screw tube 51 and a pressure board 52. The screw tube 51
is inserted through the holder frame 2 and coupled to the speed
reducing gear set 32. When rotating the speed reducing gear set 3,
the screw tube 51 is rotated to move the pressure board 52 upwards
or downwards.
[0028] Referring to FIGS. 4 and 5, the grease container 6 comprises
a container body 61 holding a lubricating grease 7, a nozzle 611
extending from the bottom side of the container body 61 and
connectable to a bearing block 8 or bushing holder 9, and a piston
62 mounted in the container body 61 and connected to the pressure
board 52 of the propelling device 5. When the control unit 4 drives
the driving mechanism 3 to rotate the speed reducing gear set 32,
the propelling device 5 is forced to move the piston 62 downwards
in the container body 61, thereby forcing the lubricating grease 7
out of the nozzle 611 into the bearing block 8 or bushing holder 9.
Because the internal pressure of the bearing block 8 or bushing
holder 9 is equal to the internal pressure of the container body
61, the internal pressure of the container body 61 is detected and
fed back to the circuit board 41 of the control unit 4 for
calculation of the dispensed amount of the lubricating grease 7,
and therefore the control unit 4 can control the lubricating grease
output amount.
[0029] Referring to FIGS. 6 and 7, during normal functioning (YES)
of the motor of the driving mechanism, the sensor 42 detects the
speed of the motor and provides the detection to the control chip
(MIC) of the circuit board 41 for reading, and the read value is
sent to a firmware of a center monitoring control and alarm system
10 wirelessly. If the value read by the control chip (MIC) of the
circuit board 41 shows abnormal (NO), the LED of the lubricating
grease dispenser is driven to provide a warning visual signal, at
the same time, the warning signal is sent to the center monitoring
control and alarm system 10 wirelessly to show the abnormal
condition.
[0030] When the center monitoring control and alarm system 10
receives a message from the control unit 4, the message enters the
system to establish system connection. In case of system connection
failure, abnormal reading, or operation interruption, the center
monitoring control and alarm system 10 immediately gives a warning
signal to indicate abnormality of the lubricating grease dispenser,
achieving auto monitoring of the lubricating grease dispenser.
[0031] Referring to FIG. 8, the firmware of the center monitoring
control and alarm system has the functions of calculation of the
amount of the lubricating grease dispensed, basic data
establishment, setting and calculation of lubricating cycle of the
lubricating grease dispenser, and recording of history data of the
lubricating grease dispenser, as well as recording of routine check
and maintenance records, and data inquiry and message update. In
case an abnormal warning is not handled or updated, the warning
status is maintained until the trouble is settled.
[0032] Referring to FIG. 9, a wireless sensor network in accordance
with the present invention is a local area network system,
comprising a plurality of wireless data block collectors 30, and a
plurality of automatic grease dispensers 20 each carrying a
transmitter. The automatic grease dispensers 20 are installed in
different mechanical parts at different locations in the factory.
The wireless data block collectors 30 collect lubricating grease
dispensing data from the automatic grease dispensers 20 wirelessly,
and then transmit collected data to the center monitoring control
and alarm system 10, and therefore the center monitoring control
and alarm system 10 achieves the functions of real-time monitoring,
auto-alarm, auto lubrication, and management control.
[0033] Although a particular embodiment of the invention has been
described in detail for purposes of illustration, various
modifications and enhancements may be made without departing from
the spirit and scope of the invention.
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