, Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to automatic lubrication systems. Particularly, but not exclusively, the disclosure relates to an online health monitoring device for DM valve and a method of operating the online health monitoring device.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present subject matter. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed subject matter, or that any publication specifically or implicitly referenced is prior art.
[0003] Automatic lubrication systems are used on many types of machinery, from large fixed plant to smaller mobile construction and mining equipment. In general, the automatic lubrication systems have replaced previous procedures requiring manual application using grease guns and the like. There is a wide range of equipment available in the market, performing a useful service in improving machine reliability, reducing the hazards of manual access to the machine, reducing the time required for maintenance and minimizing the quantity of lubricant required.
[0004] A typical automatic lubrication system includes a pumping system that receives lubricant, such as grease, from a reservoir and periodically delivers the lubricant through flow lines to a number of injectors, which, in turn, deliver prescribed amounts of the lubricant through a feed line to each lubrication point. For the sake of brevity, the connection between the pump and the injector, usually constructed from a combination of elements including pipes, tubes, and hoses.

[0005] However, the layout of lubricant flow lines for the lubrication system has complex arrangements. With such complex arrangements, installation, and supply of lubricants at, or from, each lubrication point is very difficult to maintain, thus installation and maintenance for entire lubrication system are very difficult.
[0006] At each lubrication point, a DM valve is generally disposed to control and/or regulate the delivery of the lubricant through the lubrication flow line. Thus, the monitoring of the running condition of the DM valves, during the cyclic operation, is expected to be performed. However, monitoring of the DM valves is difficult due to their unapproachable positions in the lubrication system and due to the huge quantity of the DM valves in the lubrication system.
[0007] Accordingly, there is a need for methods and systems that can overcome one or more limitations stated above or any other limitation associated with the conventional arts.
OBJECTS OF THE DISCLOSURE
[0008] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow.
[0009] A general object of the present disclosure is to reduce the number of failure due to lack of lubrication by continued monitoring of lubricant feeding through the DM valve to each lubrication point.
[0010] An object of the present disclosure is to monitor lubricant feeding through the DM valves to each of the lubrication points without using complex layout arrangements.
[0011] Another object of the present disclosure is to propose a digitalization of the process of condition monitoring and proactive maintenance of the DM valves, so as to reduce the man-hours for visual inspection and failure of equipment.
[0012] Another object of the present disclosure is to propose easy interfacing device which requires less effort for installation or replacement in case of defective.
[0013] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.
SUMMARY
[0014] This summary is provided to introduce concepts related to systems and methods for performing online health monitoring of DM valve. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0015] The present disclosure relates to an online health monitoring device for DM valve. The system includes a plurality of lubricant flow lines (11) through which a lubricant is being conveyed to bearings; a DM valve (5, 6) coupled to each line of the plurality of lubricant flow lines (11) for stroking the lubricant, wherein the DM valve includes an indicator stem having a DM valve plunger (12, 13); a push-pull button arrangement (7, 9) deployed ahead of the DM valve plunger (12, 13) in the indicator stem; and a sensor device (8, 10) coupled with the push-pull button arrangement (7, 9). The sensor device (8,10) is to receive a feedback signal from the push-pull button arrangement (7, 9) and convert that feedback signal to a signal output when the DM valve plunger (12, 13) comes in contact with the push-pull button arrangement (7, 9) during the operation of the DM valve (5, 6). The system further includes a central monitoring system (14), coupled to the sensor device (8, 10), to assess the signal output in the form of movement of the plunger (12, 13) after getting the signal output from the sensor device (8, 10) over a wireless communication network, and to provide feedback status about health of the DM valve (5, 6) over a display screen of the central monitoring system (14).
[0016] In an aspect, the central monitoring system raises an alarm if the DM valve plunger (12, 13) fails to contact push-pull button arrangement (7, 9) during operation cycle of the DM valve (5, 6), or if the lubrication status on the central monitoring system (14) is unaltered after an end of half lubrication cycle.
[0017] In an aspect, the DM valve plunger (12, 13), the push button (7, 9), and the sensor (8, 10) are equally spaced from each other.
[0018] In an aspect, the online health monitoring device comprises a battery operated with a rechargeable system by 220-230 voltage direct-current or alternating-current power supply.
[0019] In an aspect, the feedback signal is wirelessly transmitted to the central monitoring system (14) in the form of a voltage or current.
[0020] In an aspect, the bearings are part of rotating equipment.
[0021] In an aspect, the rotating equipment is a run-out table (ROT) roll or other rolls.
[0022] The present disclosure further relates to a method for operating an online health monitoring device for DM valve. The method includes receiving, at a sensor device (8, 10), a feedback signal from a push-pull button arrangement (7, 9) deployed ahead of a DM valve plunger (12, 13) in an indicator stem of the DM valve (5, 6) when the DM valve plunger (12, 13) comes in contact with the push-pull button arrangement (7, 9) during the operation of the DM valve (5, 6); converting, by the sensor device (8,10), the feedback signal to a signal output; transmitting the signal output from the sensor device (8, 10) to a central monitoring system (14); assessing, by the central monitoring system (14), the signal output in the form of movement of the DM valve plunger (12, 13); and providing feedback status about health of the DM valve (5, 6) over a display screen of the central monitoring system (14) with alarms.
[0023] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
[0024] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[0025] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
[0027] FIG. 1 illustrates a conventional DM valve arrangement for a lubrication system in bearings;
[0028] FIG. 2 illustrates a DM valve arrangement for a lubrication system in bearings in accordance with the present disclosure;
[0029] FIG. 3 illustrates exemplary DM valves in accordance with an embodiment of the present disclosure;
[0030] FIGS. 4 and 5 illustrate an internal arrangement of push-pull button arrangement and sensor device within an indicator stem of the DM valve, in accordance with an embodiment of the present disclosure;
[0031] FIG. 6 illustrates a detailed block diagram of components of a central monitoring system in accordance with an embodiment of the present disclosure; and
[0032] FIG. 7 illustrates a method for implementing a central monitoring system, according to an embodiment of the present disclosure.
[0033] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in a computer-readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION
[0034] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
[0035] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
[0036] The terms “comprises”, “comprising”, “includes” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.
[0037] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0038] Hereinafter, a description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present disclosure.
[0039] Disclosed herein are a system and a method for performing online health monitoring of DM valve. The online health monitoring device is required to avoid the human interface and ease of maintenance approach, and further avoiding the huge downtime for maintenance of the equipment of a plant.
[0040] FIG. 1 illustrates a conventional DM valve arrangement for a lubrication system in bearings. In contrast to this, FIG. 2 illustrates a DM valve arrangement for a lubrication system in bearings in accordance with the present disclosure. As shown in FIG. 2, a rotating equipment, say, run-out table (ROT) roll (2), of a plant, is supported on each end on bearings. The bearings are rotated by the help of an electrical motor (1). For lubrication, each of the bearings is connected with a DM valve (5, 6) via individual lubrication pipeline (3, 4). The DM valves (5, 6) are further connected to a plurality of lubricant flow lines (11) through which a lubricant is being conveyed to the bearings.
[0041] Exemplary DM valves (5, 6) are shown in FIG. 3 in accordance with an embodiment of the present disclosure. Each DM valve (5, 6) includes an indicator stem (14). During operation, a pressurized lubricant enters into the DM valve (5, 6) and forces a pilot piston (15) down for allowing pressure to be applied to the top of a main piston (16). The main piston (16) begins to move down under pressure and forcing the lubricant from its chamber to past the lower land of the pilot piston (15) and move out through a discharge line to the bearings.
[0042] Further, when the lubricant pressure in the lubricant flow lines (11) is changed, the lubricant enters the DM valve (5, 6) and forces the pilot piston (15) up for allowing pressure to be applied to the bottom of the main piston (16). The main piston (16) then begins to move up and forces the lubricant from its chamber to pass the upper land of the pilot piston (15) and move out of a second discharge line to the bearings.
[0043] With the above described operation, in the DM valve (5, 6), the movement of a DM valve plunger (12, 13) takes place once in forward cycle and once in reverse cycle. Further, the DM valve plunger (12, 13) gets in contact a sensor device (8, 10) of a central monitoring system (14) through a push-pull button arrangement (7, 9). Such contact information about the DM valve plunger (12, 13) with the sensor device (8, 10) is communicated through a wireless communication network to the central monitoring system (14).
[0044] The central monitoring system (14) may then assess the signal output in the form of movement of the plunger (12, 13) and provide feedback status about the health of the DM valve (5, 6) over a display screen of the central monitoring system (14).
[0045] The health monitoring process for the DM valve (5, 6) is further described in detail with reference to the central monitoring system (14) shown in FIG. 6.
[0046] FIG. 6 illustrates a detailed block diagram of components of the central monitoring system (14) in accordance with an embodiment of the present disclosure.
[0047] The central monitoring system (14) includes the processor(s) (18), the interface(s) (19), the memory (20), and the sensor device (8, 10).
[0048] The processor(s) (18) may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, logic circuitries, and/or any devices that manipulate data based on operational instructions.
[0049] Among other capabilities, the one or more processor(s) (18) are configured to fetch and execute computer-readable instructions and one or more routines stored in the memory (20). The memory (20) may store one or more computer-readable instructions or routines, which may be fetched and executed to manage warehouse over a network service. The memory (20) may include any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile memory such as EPROM, flash memory, and the like.
[0050] The interface(s) (19) may include a variety of interfaces, for example, interfaces for data input and output devices referred to as I/O devices, storage devices, and the like. The interface(s) (19) may facilitate communication of the system (14) with various devices coupled to the system (14). The interface(s) (19) may also provide a communication pathway for one or more components of the system (14). Examples of such components include, but are not limited to, central processing unit(s) (21) and data (22).
[0051] The central processing unit(s) (21) may be implemented as a combination of hardware and programming (for example, programmable instructions) to implement one or more functionalities of the central processing unit(s) (21). In examples described herein, such combinations of hardware and programming may be implemented in several different ways. For example, the programming for the central processing unit(s) (21) may be processor-executable instructions stored on a non-transitory machine-readable storage medium and the hardware for the central processing unit(s) (21) may include a processing resource (for example, one or more processors), to execute such instructions. In the present examples, the machine-readable storage medium may store instructions that, when executed by the processing resource, implement the central processing unit(s) (21). In such examples, the system (14) may include the machine-readable storage medium storing the instructions and the processing resource to execute the instructions or the machine-readable storage medium may be separate but accessible to the system (14) and the processing resource. In other examples, the central processing unit(s) (21) may be implemented by electronic circuitry.
[0052] Further, the data (22) may include data that is either stored or generated as a result of functionalities implemented by the central processing unit(s) (21). In some aspects, the data (22) may be stored in memory (20) in the form of various data structures. Additionally, data (22) can be organized using data models, such as relational or hierarchical data models. The data (22) may be stored data, including temporary data and temporary files, generated by the central processing unit(s) (21) for performing the various functions of the system (14).
[0053] In operation, referring to the description of FIG. 6, when the DM valve plunger (12, 13) comes out and in as per the operation of the DM valve (5, 6), each movement of the DM valve plunger (12, 13) confirms the lubricant going to an outlet port through pipelines (3, 4) to the bearings. During the movement of the DM valve plunger (12, 13), when the DM valve plunger (12, 13) comes in contact with the push-pull button arrangement (7, 9), the sensor device (8, 10), coupled with the push-pull button arrangement (7, 9), receives a feedback signal from the push-pull button arrangement (7, 9) and converts that feedback signal to a signal output. The signal output is then wirelessly transmitted to the central monitoring system (14) in the form of a voltage or current. The central processing unit (21) of the central monitoring system (14) assesses the signal output in the form of movement of the plunger (12, 13) after getting the signal output from the sensor device (8, 10) over a wireless communication network. Then, based on the assessment, the central processing unit (21) provides feedback status about health of the DM valve (5, 6) over a display screen of the central monitoring system (14).
[0054] For example, as shown in FIG. 2, feedback status of green color shows that the DM valve (5, 6) is working properly, while the feedback status of red color shows that the DM valve (5, 6) is not working properly.
[0055] In an aspect, the central monitoring system (14) may raise an alarm if the DM valve plunger (12, 13) fails to contact push-pull button arrangement (7, 9) during operation cycle of the DM valve (5, 6), or if the lubrication status on the central monitoring system (14) is unaltered after an end of half lubrication cycle.
[0056] In an aspect, the DM valve plunger (12, 13), the push button (7, 9), and the sensor (8, 10) are equally spaced from each other.
[0057] In an aspect, the online health monitoring device comprises a battery operated with a rechargeable system by 220-230 voltage direct-current or alternating-current power supply.
[0058] In an aspect, the feedback signal is wirelessly transmitted to the central monitoring system (14) in the form of a voltage or current.
[0059] In an aspect, the bearings are part of rotating equipment.
[0060] In an aspect, the rotating equipment is a run-out table (ROT) roll.
[0061] FIG. 7 illustrates a method for operating an online health monitoring device of lubricant DM valve, according to an embodiment of the present disclosure. The order in which the method 700 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any appropriate order to carry out the method 700 or an alternative method. Additionally, individual blocks may be deleted from the method 700 without departing from the scope of the subject matter described herein.
[0062] At block 702, the method 700 includes receiving, at a sensor device (8, 10), a feedback signal from a push-pull button arrangement (7, 9) deployed ahead of a DM valve plunger (12, 13) in an indicator stem (14) of the DM valve (5, 6) when the DM valve plunger (12, 13) comes in contact with the push-pull button arrangement (7, 9) during the operation of the DM valve (5, 6).
[0063] At block 704, the method includes converting, by the sensor device (8,10), the feedback signal to signal output.
[0064] At block 706, the method includes transmitting the signal output from the sensor device (8, 10) to a central monitoring system (14).
[0065] At block 708, the method includes assessing, by the central monitoring system (14), the signal output in the form of movement of the DM valve plunger (12, 13).
[0066] At block 710, the method includes providing feedback status about the health of the DM valve (5, 6) over a display screen of the central monitoring system (14) along with the alarms over message over phone.
[0067] The present disclosure teaches an intelligent lubrication system with proximity feedback; however, health is dependent on feedback of magnetic plunger of a DM valve. Also, to receive the proximity feedback, a signal cable arrangement is required which have same complexity as that of a typical lubrication system.
[0068] In the present disclosure, the plunger movement of the DM valve will give complete health status of the DM valve and the condition of an outlet pipe or blockage of the DM valve.
[0069] Further, in accordance with the present disclosure, the online health monitoring device, proposed herein, is having a push-pull button arrangement in an enclosed housing of a wireless communication medium. Further, a sensor of this online health monitoring device is coupled with the plunger of the DM valve through the push-pull button arrangement.
Equivalents:
[0070] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention. When a single device or article is described herein, it will be apparent that more than one device/article (whether or not they cooperate) may be used in place of a single device/article. Similarly, where more than one device or article is described herein (whether or not they cooperate), it will be apparent that a single device/article may be used in place of the more than one device or article or a different number of devices/articles may be used instead of the shown number of devices or programs. The functionality and/or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality/features. Thus, other embodiments of the invention need not include the device itself.
[0071] The specification has described a system and a method for performing online health monitoring of DM valve. The illustrated steps are set out to explain the exemplary embodiments shown, and it should be anticipated that ongoing technological development will change the manner in which particular functions are performed. These examples are presented herein for purposes of illustration, and not limitation. Further, the boundaries of the functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternative boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Alternatives (including equivalents, extensions, variations, deviations, etc., of those described herein) will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein. Such alternatives fall within the scope and spirit of the disclosed embodiments. Also, the words "comprising," "having," "containing," and "including," and other similar forms are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0072] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.

Claims:An online health monitoring device for lubricant DM valve, the system comprising:
a plurality of lubricant flow lines (11) through which a lubricant is being conveyed to bearings;
a DM valve (5, 6) coupled to each line of the plurality of lubricant flow lines (11) for stroking the lubricant, wherein the DM valve includes an indicator stem having a DM valve plunger (12, 13);
a push-pull button arrangement (7, 9) deployed ahead of the DM valve plunger (12, 13) in the indicator stem;
a sensor device (8, 10), coupled with the push-pull button arrangement (7, 9), to receive a feedback signal from the push-pull button arrangement (7, 9) and convert that feedback signal to a signal output when the DM valve plunger (12, 13) comes in contact with the push-pull button arrangement (7, 9) during the operation of the DM valve (5, 6); and
a central monitoring system (14), coupled to the sensor device (8, 10), to:
assess the signal output in the form of movement of the plunger (12, 13) after getting the signal output from the sensor device (8, 10) over a wireless communication network, and
provide feedback status about the health of the DM valve (5, 6) over a display screen of the central monitoring system (14).
2. The online health monitoring device as claimed in claim 1, wherein the central monitoring system (14) raises an alarm if the DM valve plunger (12, 13) fails to contact push-pull button arrangement (7, 9) during operation cycle of the DM valve (5, 6), or if the lubrication status on the central monitoring system (14) is unaltered after an end of half lubrication cycle.
3. The online health monitoring device as claimed in claim 1, wherein the DM valve plunger (12, 13), the push button (7, 9), and the sensor (8, 10) are equally spaced from each other.
4. The online health monitoring device as claimed in claim 1, wherein the online health monitoring device comprises a battery operated with a rechargeable system by 220-230 voltage direct-current or alternating-current power supply.
5. The online health monitoring device as claimed in claim 1, wherein the contact signal is wirelessly transmitted to the central monitoring system (14) in the form of a voltage or current.
6. The online health monitoring device as claimed in claim 1, wherein the bearings are part of rotating equipment.
7. The online health monitoring device as claimed in claim 6, wherein the rotating equipment is a run-out table (ROT) roll or other rolls.
8. A method for operating an online health monitoring device of lubricant DM valve, the method comprising:
receiving, at a sensor device (8, 10), a feedback signal from a push-pull button arrangement (7, 9) deployed ahead of a DM valve plunger (12, 13) in an indicator stem of the DM valve (5, 6) when the DM valve plunger (12, 13) comes in contact with the push-pull button arrangement (7, 9) during the operation of the DM valve (5, 6);
converting, by the sensor device (8,10), the feedback signal to a signal output;
transmitting the signal output from the sensor device (8, 10) to a central monitoring system (14);
assessing, by the central monitoring system (14), the signal output in the form of movement of the DM valve plunger (12, 13); and
providing feedback status about the health of the DM valve (5, 6) over a display screen of the central monitoring system (14) along with alarms message over the phone.