FIELD OF INVENTION
[001] The present disclosure relates to proactive condition monitoring of an equipment, more particularly, the present disclosure relates to monitoring and providing feedback regarding grease flow in the equipment, to prevent premature failure of the equipment.
BACKGROUND OF THE INVENTION
[002] Equipment such as Bearing assemblies are used in a very wide range of applications. Lubrication of a bearing assembly is essential. It is known in the art to achieve lubrication of a bearing assembly by pumping a continuous through-flow of grease through the bearing assembly.
[003] For example, in casting equipment grease is usually fed into a bearing cavity of the bearing assembly via the bearing housing. Typically, certain quantity (few cc) of grease is fed in per pump cycle with a pump cycle occurring at certain interval (10 to 20 minutes). The grease exits the bearing assembly via seals between the bearing housing and the rotating shaft or via exit holes in the bearing housing or seal carriers. The grease outflow from the bearing helps to prevent the ingress of contaminants. However, due to leakage in the bearing assembly, the quantity of grease flowing reduces over time, thereby leading to lack of lubrication in the bearing assembly.
[004] Lack of lubrication is one of the most important failures reason & major contributor for failures of bearing element or equipment’s. Thus, continuous measuring or monitoring of the grease quantity at each point in a bearing assembly system is vital. Further, the bearing assembly includes certain critical and intricate locations that are difficult for human intervention to take timely action. But non- availability of an apparatus of method or system in the field for monitoring flow of high viscous media i.e. grease flowing through a conduit of size

8-10 mm is a major concern. Further, early failure indication for the main bearings permits a scheduled main bearing replacement or maintaining proper quantity of grease, thus avoiding irreparable damage to the machine while avoiding unnecessary maintenance and exhaustive inspection procedures.
PRIOR ART:
[005] Now, reference may be made to the following prior arts discussing state of
the art techniques.
[006] In 236/KOL/2006 teaches a device for feeding of grease in work roll bearings and, in particular, to a system for required controlled flow feeding of grease in work roll bearings. The system basically involves a dose feeder(DF) means adapted to feed said desired selective amounts of grease in bearings; means to operate the dose feeder means(DS) at high pressure to ensure uniform distribution of grease inside the bearing(BE);and monitoring device(MM) adapted to monitor the exact amount of grease feeding through the said dose feeders(DF).Importantly, the system for feeding of g r e a s e in wor k roll bearings in a d a p t e d to ensure feeding of exact amount of grease in the bearings(BE). The system can be adv antageously used t o feed grease in r o l l choke bearings and in other roll ing mill areas such as finishing strands i n Hot Strip Mill, Skelp Mill and the like.
[007] CN201875419U provides: An intelligent lubricating grease flow meter belongs to the field of supply flow control of a grease centralized lubricating system, comprises a valve body and plungers, and is characterized in that the valve body is provided with a plurality of tap holes, each tap hole is provided with the plunger, wherein one plunger is a magnetic plunger, the magnetic end of the magnetic plunger is connected with a proximity switch combination, the two ends of each taphole of the valve body are plugged by the plungers, and all the outlets are plugged by spiral plugs except a grease outlet. The intelligent lubricating

grease flow meter can be arranged in one set of grease centralized lubricating system, different lubricating devices are grouped according to the lubricating characteristics of the lubricating devices for controlling the flow, during the operation process, the flow values are respectively set on various intelligent lubricating grease flow meters, when all lubricating flows suffer failure, the intelligent lubricating grease flow meters send the flow variation alarm signal to a main control room, if the flow of an oil supply branch is suddenly increased, pipe breakage or pipe joint leakage are probably generated in the branch, and if the flow of the oil supply branch is suddenly decreased, the branch is probably blocked.
[008] All these prior art methods have disadvantages, as their subject matter fails to provide a proactive failure prevention method or device, capable of providing a quantitative feedback about grease flow in an equipment. The prior arts also failed to address the problems discussed above.
OBJECTS OF THE INVENTION
[009] An object of the invention is to reduce the failure of the equipment like
bearing assemblies due to lack of lubrication.
[0010] Another object of the invention is to provide continuous monitoring of grease / lubricant flow, and feedback about the grease / lubricant flow.
[0011] Another object of the invention is to provide a digitalize process of condition monitoring & proactive maintenance of equipment, to reduce man-hours for visual inspection, and failure of equipment.

SUMMARY OF THE INVENTION
[0012] The present disclosure relates to a grease flow monitoring system (500). The grease flow monitoring system (500) includes a bearing assembly having an ROT roll (2), the ROT roll (2) includes two bearing housing configured to rotate through an electrical motor (1); a plurality of DM valve (6, 7) coupled to the bearing housing through grease pipe line (3, 4); a plurality of grease flow meter (5, 8) installed at discharge ports of the DM valve (6, 7). The grease flow meter (5, 8) includes an internal gear arrangement, working on positive displacement principle, having gear shafts configured to rotate as grease flows through grease flow meter (5, 8), and a local display unit coupled to the internal gear arrangement through a pulse arrangement (11, 12), wherein the pulse arrangement (11, 12) provides continuous feedback regarding grease flow on the local display unit. The grease flow monitoring system (500) further includes a central display unit (9) coupled to the local display unit, the central display unit (9) configured to receive and display the feedback regarding grease flow, and generate an output based on a deviation of grease flow form a predefined output flow value of the DM valve (6, 7).
[0013] When the pump runs during the operating cycle, the changeover valve to the direction of grease flow either A or B line.
• Further Various DM valves are connected with A & B line in series i.e all DM valves will purge out as the grease as it reach to the each DM valve.
• Once the grease enters in to DM valve pushes the piston of DM valve and purge out the accumulated grease of opposite end of chamber.
• Based on the above operation DM valve, piston moves forward or reverse.

• Further purged out grease of DM valve enter in to the online real-time grease flow meter which is coupled just after the each DM valves, rotates the gears (flow meter consist of oval gear arrangement along with pulse counter).
• Once the gear rotates it transmitted the pulse out data wirelessly to the central display unit located in the Control room.
• Also, as per pulse data, preset valve of flow based on the calibration record it will provide the flow quantity as well as generated the alarming and warning
• Once grease passed through flow meter it will entered in the consumable point like bearing etc.
• Hence failure of bearing will be eliminated because of lack of lubrication.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0014] Further objects and advantages of this invention will be more apparent from the ensuing description when read in conjunction with the accompanying drawings of the exemplary embodiments and wherein:
Figure 1 shows: A prior art greasing system in a roll bearing.
Figure 2a-b shows: Constructional features of a state of the art DM valve.
Figure 3 shows: Operational features of a state of the art DM valve.
Figure 4a-b shows: A right view and a left view respectively of a three-valve DM block in accordance with an embodiment of the present disclosure.

Figure 5 shows: A grease flow monitoring system 500 in accordance with an embodiment of the present disclosure.
[0015] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING
DRAWINGS
[0016] The present invention, now be described more specifically with reference to
the following specification.
[0017] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation,

together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0018] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0019] Fig. 1 illustrates a prior art greasing system in a roll bearing. The greasing system includes the following components:

[0020] Figs. 2a, 2b, and Fig. 3 illustrate constructional and operational features of a state of the art DM valve. Fig. 2a provides typical one valve DM block. Valve has a discharge port on the bottom. A four-valve block would have four discharge ports. The DM block includes:
- Supply ports from pump

- Adjustment screw (varies valve output)
- Indicator stem (shows that valve is operating)
- Check valve (required in discharge port of some oil systems)
Fig. 2b provides an exemplary three-valve DM block having three discharge ports.
[0021] Fig. 3 provides operational characteristics of a typical DM valve. DM Valves are completely hydraulic in operation and will deliver either oil or grease. These valves are also fully and individually adjustable in regard to discharge quantity and are equipped with operational indicators. DM valves have one discharge port per valve section located on the bottom of the valve. DM valves are available in several basic discharge capacities and are available in blocks consisting of one, two, three or four valves.
[0022] Operation of the typical DM valve includes: Pressurized lubricant entering the valve forces the pilot piston down, allowing pressure to be applied to top of the main piston. The main piston begins to move down under pressure, forcing lubricant from its chamber, past the lower land of the pilot piston and out the discharge line to the bearing. When pressure in the supply line is reversed, lubricant then enters valve and forces the pilot piston up, allowing pressure to be applied to bottom of main piston, which begins to move up, forcing lubricant from its chamber, past the upper land of the pilot piston and out the second discharge line to the bearing.
[0023] Figs. 4a and 4b illustrates a right view and a left view respectively of a three-valve DM block in accordance with an embodiment of the present disclosure. As shown in Figs. 4a and 4b, the DM valve block is provided with a grease flow meter (5, 8). Fig. 4a, the right view shows a local display unit or a flow meter provided at each discharge port of the DM valve block. Fig. 4b, the left view shows an internal arrangement of the local display unit or the flow meter. The internal arrangement includes a pair of internal oval gears having a positive

displacement working principle. In an embodiment as shown in Figs. 4a & 4b, pitch or spacing of the grease flow meter (5, 8) is similar to the discharge ports of the DM valve block.
[0024] In operation the grease flow meter (5, 8) are provided on the discharge outlets of the DM valve, such that the grease discharged from the DM valve passes through the grease flow meter (5, 8). As the grease passes through the grease flow meter (5, 8), gear shaft of the internal oval gears rotates as the gear rotates. Rotation of the gear is proportional to a greasing cycle associated with the roller bearing. In an embodiment, the gear shaft of the gears is coupled with a signal cable (cable / pulse arrangement), and is configured for providing continuous feedback regarding flow of grease passing through the grease flow meter (5, 8) based on the rotation of gears and in turn rotation of the gear shaft. In an embodiment, the grease flow meter (5, 8) may also be provided with proximity sensors, magnetic indicators or the like devices that may assist in providing continuous monitoring and feedback regarding grease flow.
[0025] The positive displacement working as mentioned earlier includes constant rotation of the gears with the passage of grease, and in turn provision of continuous feedback about flow of grease. In an embodiment, the gear shaft of the gears is coupled to the local display unit through the pulse arrangement mentioned earlier, wherein feedback regarding flow of grease is displayed on the local display unit of the grease flow meter (5, 8). In an embodiment, the grease flow meter (5, 8) operates on one of a DC or AC power or battery operated providing 220-230 V supply. In an embodiment, the feedback may include quantity, quality, temperature, density, or the like characteristics of the grease flowing through the roller bearing. Further, the feedback is provided in a digitalize manner on the local display unit, so that an operator / maintenance engineer may proactively take corrective action to prevent premature failure of the equipment or the roller bearing. The feedback may also provide an assessment regarding the life

of the equipment or the roller bearing. It is further ensured that the grease flow meter (5, 8) works in a leakproof environment to provide an error free feedback regarding grease flow.
[0026] Fig. 5 illustrates a grease flow monitoring system 500 in accordance with an embodiment of the present disclosure. The grease flow monitoring system 500 includes the following components in addition to the components associated with the prior art greasing system of the roll bearing described earlier with reference to Fig. 1. The components include:

[0027] Operation of the grease flow monitoring system 500: With reference to FIG. 5, ROT roll (2) includes two bearing housing configured to rotate through the electrical motor (1). Each bearing housing is connected with the DM valve (6 & 7) via individual grease pipe line (3 & 4). Further the grease flow meters (5 & 8) are installed at output of the DM valve (6 &7).
[0028] As described earlier, the grease flow meter (5, 8) includes a pulse arrangement (11 & 12) to provide the continuous feedback regarding grease flow in the system 500 through the pulse signal provided on the local display unit. In an embodiment, the feedback and monitoring status as provided to the local display unit is presented on a central online display unit (9), wherein the local display unit is coupled to the central online display unit over a wireless or wired medium. The grease flow meter (5, 8) are provided with power source of 230 voltages (15 &16). In an example, under normal condition, the DM valve (6, 7)

gives the output flow based on the selected valve body, for example 5CC/stroke. Hence, values corresponding to acceptable limit associated with the DM valve (6, 7) is defined in the display unit (10). Further, any deviation from the threshold value in the system will display via display unit (9) to provide a warning signal to the operator / maintenance engineer about the potential danger or maintenance requirement or corrective action, thereby enabling proactive maintenance and preventing failure of the roller bearing. In an embodiment, the warning signal may include audio, video, wireless, tactile, text message, or the like. The warning signal may also be received on a device carried by the operator / maintenance engineer.
[0029] It is to be noted that the present invention is susceptible to modifications, adaptations and changes by those skilled in the art. Such variant embodiments employing the concepts and features of this invention are intended to be within the scope of the present invention, which is further set forth under the following claims.

WE CLAIM:
1. A real time online grease flow monitoring system comprising:
a plurality of grease flow lines (10) through which grease being conveyed to bearings;
at least one DM Valve (6) coupled in line of the plurality of grease flow lines (10) for stroking the grease;
a flow meter (5) deployed ahead of the DM Valve (6) through which the grease flows, when the DM valve (6) is in operation, the flow meter (5) comprising a pair of gears wherein each rotation of gear teeth designates equivalent quantified greasing volume, the flowmeter (5) further comprising a pulse counter (11) to capture the rotation signal from the flowmeter (5), the flowmeter (5) being coupled to a central monitoring system (500) to which the flowmeter (5) transmits the rotation signal; and
the central monitoring system (500) is being configured to assess the rotation signal in the form of greasing volume (cc/stroke), received from the pulse counter (12) of the flowmeter (5), when the DM valve (6) being operation, and subsequently gives feedback over a screen (9) coupled to the central monitoring system (500) and raises alarm if the threshold amount of grease is not flowed through the DM valve (6).
2. The real time online grease flow monitoring system as claimed in claim 1,
wherein the flowmeter (5) has oval gear arrangement.

3. The real time online grease flow monitoring system as claimed in claim
1, wherein the flowmeter (5) operates on 220-230 V DC or AC power
supply.
4. The real time online grease flow monitoring system as claimed in claim 1, wherein the flowmeter (5) is battery operated.
5. The real time online grease flow monitoring system as claimed in claim 1, wherein the rotation signal is wirelessly transmitted to the central monitoring system (500) in the form of a pulse.
6. The real time online grease flow monitoring system as claimed in claim 1, wherein the bearings is part of rotating equipment.
7. The real time online grease flow monitoring system as claimed in claim 6,
wherein the bearings is part of ROT rolls.