FIELD OF THE INVENTION
The present invention relates to a Flux Crusher Lubrication System involving a switching
apparatus for use as a line leakage detector in grease lubrication unit. More particularly, the
present invention is directed to a small electrical switch such as a door switch, with a very
less operating distance, capable of precisely detecting the small movement of the plunger,
in or out of the distribution box to actuate changeover of grease line for pumping in grease
in alternate lines in Flux Crusher Lubrication System in steel plant. Advantageously, the
door switch with attachments in the flux crusher lubrication system according to the present
invention is capable of detecting line leakages corresponding to small movements around 3
to 8 mm of plunger in a reliable manner, even in a dusty area, for pressure sensitive
distribution of grease in alternate lines of the flux crusher lubrication system.
BACKGROUND OF THE INVENTION
In a conventional Flux Crusher lubrication system, a small inductive proximity switch is used
to detect line leakage. There are two grease lines wherein grease is pumped into one line at
a time by a grease pump and after a certain pressure is achieved, it automatically changes
over to the other line. While changing over a tiny plunger moves in our out of the
distribution box. The thickness of the plunger is around 1.5 mm and the lateral movement is
around 10 mm. In case of line leakage, line pressure will not build and there will be no
movement of the plunger and the change over cannot be effected. A very small inductive
proximity switch is conventionally used to sense the plunger movement to detect line
leakage which fails to detect plunger movement in case of line leakage. The performance of
the inductive proximity switch is also adversely affected due to presence of excessive dust
in the surroundings.
Thus the existing inductive proximity switch of the flux crusher lubrication system suffered
from the following limitations and disadvantages:
1) The existing device use to malfunction because of excessive dust.
2) Maintainability of the device is a problem as it is fragile.
3) Being an imported item it is not easily available and costly also. Indian made
substitutes are also not available.

There has been therefore a need in the related field of flux crusher lubrication systems to
developing a line leakage detection device which would detect even very small lateral
movements of plunger of distribution box and also enable lubrication with grease in
alternate lines in a reliable manner unaffected by presence of dust.
OBJECTS OF THE INVENTION
The basic object of the present invention is thus directed to providing a flux crusher
lubrication system involving an electrical switch capable of detecting line leakage in a
reliable manner.
A further object of the present invention is directed to providing a flux crusher lubrication
system involving an electrical switch which would be capable to detect very small plunger
movement of the distribution box of the lubrication system in flux crusher including line
leakage.
A still further object of the present invention is directed to providing a flux crusher
lubrication system involving an electrical switch which would be capable of distributing
grease in alternate lines by effective detection of small plunger movement of distribution
box depending on line pressure.
A still further object of the present invention is directed to providing a flux crusher
lubrication system involving an electrical switch which would ensure reliable detection of line
leakage and desired distribution of pumped grease in alternate lines in the lubrication
system.
Yet another object of the present invention is directed to providing a flux crusher lubrication
system involving an electrical switch which is a physical contact switch and the contact
block is protected from dust so that it does not malfunction due to dust.
A further object of the present invention is directed to providing a flux crusher lubrication
system involving an electrical switch preferably door switch which would be robust
compared to the conventional inductive proximity switch and is easy to fit and adjust and
also easy to diagnose.

A still further object of the present invention is directed to providing a flux crusher
lubrication system involving an electrical switch which would be made of components that
are easily available and are cheap and is very easy to fabricate.
SUMMARY OF THE INVENTION
The basic aspect of the present invention is thus directed to a Flux Crusher Lubrication
System involving line leakage detection comprising
distribution box having grease lines and operative grease pump adapted to pump
grease into one line at a time and after a certain pressure is achieved automatically
change over to the other line, a tiny plunger adapted to move in and out of the
distribution box during changeover with no movement of said plunger indicative of
line leakage ;
a lubrication monitor with means to sense line leakage operatively connected to said
plunger comprising a small switch with a very less operating distance, for detecting
the small movement of the plunger directly linked to said plunger to sense said small
movement of said plunger or no movement of said plunger indicative of line
leakage.
A further aspect of the present invention is directed to a flux crusher lubrication system
involving line leakage detection wherein said means to sense line leakage comprises a door
switch having a round and small striking surface which is cooperatively connected to said
plunger via a brass rivet and a straight through lug.
A still further aspect of the present invention is directed to said flux crusher lubrication
system wherein said striking surface cooperatively connected to said plunger via a brass
rivet and a straight through lug includes adhesive for rigidity in cooperative connection.
A still further aspect of the present invention is directed to said flux crusher lubrication
system wherein said door switch is a physical contact switch having the contact block
protected from dust to avoid malfunction due to dust.

The objects and advantages of the present invention are described hereunder in greater
details with reference to the following accompanying non limiting illustrative drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1: is the photographic image of the electrical switching apparatus for the flux crusher
lubrication system according to the present invention showing its different components
separately.
Figure 2: is the photographic image of the electrical switching apparatus wherein the
components of the device are shown in assembled condition using adhesive.
Figure 3: is the schematic diagram showing the comparative layout of the flux crusher
lubrication system wherein disposition of the electrical door switch apparatus used in
relation to flux crusher lubrication unit has been shown.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE
ACCOMPANYING DRAWINGS
The present invention is directed to providing a flux crusher lubrication system involving a
switching apparatus for use as a line leakage detector in grease lubrication unit and in
particular to a small electrical switch such as a door switch, with a very less operating
distance, capable of precisely detecting the small movement of the plunger, in or out of the
distribution box during changeover of grease line for pumping in grease in alternate lines in
Flux Crusher Lubrication System in steel plant. The thickness of the plunger of lubrication
distribution box is around 1.5 mm and the usual lateral movement is around 10 mm.
However, if there is line leakage, the plunger do not move causing operational problem of
the system.
A small electrical switch with a very less operating distance, mainly door switch, is provided
by way of the present invention for detecting the small movement of the plunger. The door
switch has a round and small striking surface which cannot be operated by the plunger
without a suitable attachment. So an attachment is made with the door switch by fixing a
brass rivet and a straight through lug assembled with adhesive.

Accompanying Figure 1 is the photographic image of the electrical switching apparatus for
the flux crusher lubrication system according to the present invention showing its different
components separately. Accompanying Figure 2 is the photographic image of the electrical
switching apparatus wherein the components/attachments of the device are shown in
assembled condition using adhesive. This switching apparatus is useful in detecting small
movements around 3 to 8 mm, even in a dusty area. This is a physical contact switch and
the contact block is protected from dust so that it does not malfunction due to dust.
Accompanying Figure 3 is the schematic diagram showing the comparative layout of the
lubrication system of flux crusher lubrication system wherein disposition of the electrical
door switch apparatus used in relation to flux crusher lubrication unit in lieu of proximity
switch has been shown. It may be noted that the door switch is installed adjacent to and
aligned with the plunger of the distribution box of flux crusher lubrication unit such that the
brass rivet attached to the switch is in contact with the plunger. Any small movement of the
plunger in the range of 3-8mm is detected by the door switch via a lubrication monitoring
unit and the changeover is effected for supplying grease from one distribution line to the
other. Also the switch is capable of leakage detection in any of the lubrication lines.
The normally open contact of the door switch is connected to the lubrication monitor and
whenever the switch is operated a 24 volt signal is received by the monitor. The grease
monitor gives an ON command to the pump and whenever line pressure is achieved it shifts
to another line and the plunger at the distributer moves in or out and the door limit switch
gets operated. The monitor is programmed in such a way that when lubrication ON
command is given it starts the pump for a maximum time of around a minute (which is
programmable). If there is no line leakage in any of the lines all the lines will get greased in
a cycle and required numbers of 24 volt electrical pulses will be received by the monitor
within the programmed time and the pump will get OFF at the end of the cycle and timer for
the OFF time, usually around one hour, is set to ON. Again the process will start after the
OFF time. The Maximum run time, numbers of pulses and OFF time are programmable as
per requirement of the lubrication system. Now if there is any leakage in a line, pressure
will not build in that line and the required number of pulses will not be there within the
maximum ON time. So the monitor will get OFF after the maximum ON time is over and a
fault alarm will be generated thus detecting the leakage.

This device is much robust compared to the conventional inductive proximity switch and is
easy to fit and adjust and easy to diagnose. The components are easily available and are
cheap and also very easy to fabricate.
It is thus possible by way of the present invention to providing a flux crusher lubrication
system involving an electrical contact switch for detecting line leakage in flux crusher
lubrication system and effectively control the changeover of the pumped grease supply
through the alternate lubrication supply lines in a reliable manner by detecting very small
movements of the order of 3-8mm of the plunger of the distribution box. Advantageously,
the contact block of this physical contact switch is protected from dust so that it does not
malfunction due to dust thus favouring wide scale application in various lubrication systems
in steel plants and other industries.

We Claim:
1. A Flux Crusher Lubrication System involving line leakage detection comprising
distribution box having grease lines and operative grease pump adapted to pump
grease into one line at a time and after a certain pressure is achieved automatically
change over to the other line, a tiny plunger adapted to move in and out of the
distribution box during changeover with no movement of said plunger indicative of
line leakage ;
a lubrication monitor with means to sense line leakage operatively connected to said
plunger comprising a small switch with a very less operating distance, for detecting
the small movement of the plunger directly linked to said plunger to sense said small
movement of said plunger or no movement of said plunger indicative of line
leakage.
2. A flux crusher lubrication system involving line leakage detection as claimed in claim
1 wherein said means to sense line leakage comprises a door switch having a round
and small striking surface which is cooperatively connected to said plunger via a
brass rivet and a straight through lug.
3. A flux crusher lubrication system as claimed in anyone of claims 1 or 2 wherein said
Striking surface cooperatively connected to said plunger via a brass rivet and a
straight through lug includes adhesive for rigidity in cooperative connection.
4. A flux crusher lubrication system as claimed in anyone of claims 1 to 3, wherein said
door switch is a physical contact switch having the contact block protected from dust
to avoid malfunction due to dust.

ABSTRACT

A Flux Crusher Lubrication System involving a switching apparatus is disclosed for use as a
line leakage detector in grease lubrication unit in steel plant. More particularly, the Flux
Crusher Lubrication System is equipped with a small electrical switch such as a door switch,
with a very less operating distance, capable of precisely detecting the small movement of
the plunger, in or out of the distribution box to actuate changeover of grease line for
pumping in grease in alternate lines in the Lubrication System. Advantageously, the door
switch with attachments in the flux crusher lubrication system according to the present
invention is capable of detecting small movements around 3 to 8 mm of plunger in a reliable
manner, even in a dusty area, for pressure sensitive distribution of grease in alternate lines
of the flux crusher lubrication system.