1. Overview
　　

The visualization of intelligent lubrication is to set each lubrication point, each oil supply amount, and the cycle interval on the display screen of the lubrication equipment; fault alarm display; automatic lubrication, manual lubrication, and remote start-stop operations can be performed for each lubrication point. Operate and display on the display. Visualization of lubrication equipment. The flow controller of each lubrication point automatically responds to the instructions from the display screen. Serial network communication is used to transmit the instructions between the flow controller and the operating system of the display screen. The oil pressure of the lubrication pump can be set at 10 ～ 40MPA.

With single-line conveying, the lubrication pump and fuel pump are automatically controlled by dry thin oil lubrication of the electronic control system. It is an advanced lubrication equipment with mechatronics, high automation and networking.

The visual intelligent lubrication equipment has the advantages of convenient operation, controllable oil quantity, and reliable operation; there is no need for manual intervention on site, one-to-one fault alarm and high degree of automation are displayed. Due to the high height of the crane equipment in the port, the structure is more complex, and other mechanical systems The lubrication points are also arranged in difficult to maintain places, which brings certain difficulties to the maintenance operation of the lubrication system. If intelligent lubrication equipment is used, the lubrication system can be directly controlled on the operation screen, and the system operating conditions can be directly seen on the screen. This is not possible with ordinary lubrication. Therefore, intelligent lubrication is widely used in metallurgy, cement, ports, and other industries.

The ordinary lubrication system cannot see the oil supply situation of each bearing on the electric control box. If the equipment has a fault, the lubrication point will be degreased and damaged for a long time, causing serious losses or causing some lubrication points to be too much oil and wasted. Intelligent lubrication adopts volumetric oil supply method. The system's oil supply accuracy is extremely high, and the oil supply amount can be set, the interval can be set, and the fault can be alarmed. The serial bus communication mode is simple and reliable. It is a truly intelligent lubrication equipment.

The main features of smart lubrication are as follows:

1. The amount of oil for each lubrication point can be set arbitrarily on the man-machine interface. Good amount of oil.

2. The lubrication time and interval time of each lubrication point can be set arbitrarily on the man-machine operation interface.

3. Once the lubrication point of a certain lubrication point is blocked or oil does not come out for other reasons, the point of failure will be displayed on the man-machine interface and an alarm will be issued.

4. The human-machine interface display device with touch screen or Chinese display displays the operating status to realize visual operation.

5. Using digital information technology and serial bus communication technology to make the equipment miniaturized and networked.

6, using volumetric oil control system, high accuracy of oil supply.

7, one-to-one point-by-point control of oil supply, concentrated oil pressure, high pressure, easy to pressure to the bearing.

8. The system uses one lubrication pump and one fuel pump.

9. The system uses a microcomputer-controlled file display to visualize the lubrication process.

10. The lubrication system and the central control room are hard-connected with DCS. Can realize central control start-stop and fault alarm.

Since intelligent lubrication has the characteristics of visualization, networking, and high automation, ordinary lubrication is unmatched. It is a modern lubrication equipment that upgrades the product grade and improves the reliability of the equipment. It is a good choice for the lubrication equipment of port cranes, steel plants, cement plants and other departments.

Because the old ordinary dry oil lubrication system does not have a flow detection system, once the oil circuit is blocked or no oil can not be displayed, it will cause long-term degreasing and burn the bearing.

Because the old common dry oil lubricating system has a fixed amount of oil for each time, the amount of oil is too much or too little, resulting in damage to bearings or waste of lubricating oil.

Because there are many non-volume or non-bus type quasi-intelligent lubrication on the market at present, non-volume lubrication system adopts the control of the time to open the solenoid valve to control the amount of oil. Due to the influence of the pressure of the oil circuit, the error of the oil supply is extremely large. There is also non-bus-type intelligent lubrication, which uses a large number of cables to achieve switching or parallel communication, which makes the system complex and prone to failure. Users must carefully consider when choosing to avoid unnecessary losses.

2.the system works
　　

HRZN-1 microcomputer controlled intelligent lubrication system consists of electric lubrication pump, electric refueling pump, electric control box with man-machine interface, electronic flow controller, dry oil filter, pressure switch, oil pipeline, communication bus and other parts.

The electric lubricating pump mainly sends the lubricating oil in the oil drum to the oil pipeline, so that the pressure in the oil pipe is kept in the range of 10-40Mpa, and the intelligent distributor is provided with a certain amount of lubricating oil. The electronic flow controller automatically feeds the bearings regularly and quantitatively according to the preset oil quantity and interval time by the user. The lubrication pump has a pressure regulating valve, and the output oil pressure is adjusted by the user according to actual needs.

The man-machine interface of the intelligent lubrication system can set the oil quantity and interval time of each lubrication point. The main menu has four modes: remote control, automatic operation, manual control, and setting change. The user can choose according to needs.

In the operating mode, the electronic control system circulates oil to each oil point in turn. First, the electric control box control system starts the lubrication pump and waits for the pressure switch to act. When the pressure reaches the set value, the pressure switch acts, and then communicates to the need via the communication bus. The refueling electronic flow controller sends a refueling instruction. After the corresponding electronic flow controller receives the instruction, it starts to press the oil according to the preset oil amount. The man-machine interface displays the oil point number of the bearing. The fault or normal information returned to the flow controller is displayed on the display, and then the refueling action of the next lubrication point is started. After the refueling is completed, the lubrication pump is turned off and the display starts to count down. Because there is an error in the refueling time at each oil point, the next refueling may not be performed in order.

The electronic flow controller is numbered, and the number corresponds to the bearing. The electronic flow controller uses the oil pressure piston to press the grease in the oil chamber into the bearing in a volumetric manner. The accuracy of the oil supply is very high, and the pressure of the oil circuit is high. High or low does not affect the lubrication accuracy.

The work of the electronic flow controller is connected to the electric control box through the communication bus. The control system of the electric control box directs the work of all electronic flow controllers with digital instructions.

The working power supply of the electronic flow controller is AC26V safety voltage. The power to the oil valve body is driven by a DC motor. There is a flow detection switch on the valve body. Each time the oil pressure piston moves, the flow detection switch sends a signal. This signal reflects both The flow rate also reflects whether the valve body is out of oil. If there is no signal in the oiling time, it means that there is no oil out, it is regarded as a failure. The number of signal pulses in the oiling time is multiplied by the amount of oil each time = the total oil amount of that time. So the electronic flow controller is the core of the system.

The electric refueling pump is used to replenish the oil storage barrel of the lubricating pump. The barrel is equipped with a liquid level switch. When the oil level in the oil barrel is low, the low level switch point is closed. When rising to a high liquid level, the fuel pump is turned off. This process is done automatically by the control system.

3.use

1. The installation of the oil pipeline supervisor and the oil pipeline branch pipe must be neat and beautiful, and the inside of the pipe must be kept clean and free from high temperature baking and low temperature freezing.

2. The installation position of the lubricating oil pump and electronic flow controller must be protected from wind, snow, rain, sun exposure, strong vibration, high temperature baking, and low temperature freezing, and the maintenance distance of the equipment must also be considered.

3. The numbers of electronic flow controllers in the same lubrication system cannot overlap, and the numbers start from 0 to the end, and can be installed out of order.

4. The communication combination cable should be placed in the bridge or the conduit, to avoid high temperature areas. The power and communication lines in the cable cannot be reversed, otherwise the controller will be burned. The power line is a thicker wire, and the communication line is more Thin wires, power wires are AC non-polar, communication wires are divided into A and B wires, and must not be reversed!

5. The pipes and circuits of the lubrication system must be connected according to the drawing, and must be correct.

6. When used for the first time, after the power is turned on, the transfer switch is switched to the manual start-up lubrication pump. After the lubrication pump starts, wait for the pressure on the pressure gauge to rise. If the pressure is not suitable, you can adjust the pressure adjustment valve on the lubrication pump to make the pressure At the appropriate position, the pressure is set according to the length of the oil pipe diameter and the viscosity of the grease, which is generally set between 10-30Mpa.

7. After power-on, first set the oil quantity and interval time of each lubrication point. For the setting method, see the operation of the display.

8. The central control start-stop lubrication system must use passive dry contacts. The dry contact sent by the DCS signal to the central control room is 24V1A. If the user applies a high voltage of 220V to the contact, it is easy to damage and interfere with the display.

9. Lubrication equipment must have a good safety ground to prevent electric shock.

4.the basic configuration of HRZN-1 intelligent lubrication电动润滑泵 HRBZN-D100 0～40Mpa

Electric gasoline pump HRB-D3.3

Microcomputer display HRZN-1 LCD12864

Electronic flow controller 0 # ～ 250 # according to actual needs

Main oil pipe ￠ 18 × 3 stainless steel pipe

Oil pipe ￠ 14 × 2 stainless steel pipe

Flow controller output tubing ￠ 14 × 2 stainless steel tube

Power communication line 1.5 × 2 + 0.75 × 2 mm2 Four-core twisted pair shielded cable

5.the configuration of various series

1. HRZN-1 microcomputer controlled LCD12864 liquid crystal display monitor

2.HRZN-2 computer monitor display

3.HRZN-3 touch screen monitor display

4.HRZN-4 Ethernet connection computer monitoring display

6.the main parameters

1. Working pressure 10 ～ 40Mpa Set according to the situation

2. Each time the amount of oil is 0 ～ 255 × 0.5ml, set by the user as required

3. Cycle interval time: 0 ～ 255 × 0.5 hours. User set as required

4.Fault alarm Display shows sound and light alarm

5. Remote control Central control start-stop system and fault alarm (DCS connection)

6.Display mode LCD display

7.Bus mode Serial bus

8.Input voltage AC 380V three-phase three-wire system

9. Flow controller input voltage AC26V (internally generated)

10. Ambient temperature -20 ° ～ 50 °

11.Ambient humidity 85%

7.Common troubleshooting methods

HRZN-1 microcomputer display control is the core controller of the intelligent lubrication system. All functions of the system can be controlled on this man-machine interface.

After the system is powered on, press the "Start / Stop" key to enter the main menu. The main menu contains: remote control, automatic control, manual control, and change the four settings. Press the up and down keys to move the arrows to point to different items. When the “Start / Stop” key is pressed, the system automatically executes the item pointed by the connector.

The system's oil quantity and cycle interval can be set. As long as the arrow points to the "Change Settings" item and press the "Start / Stop" key, the setting menu will be displayed. The oil quantity unit is 0.2ml, and the oil quantity can be between 0-255. Set between. The time unit is 0.5 hours. The interval can be set between 0-255. Press the "M" key to move the cursor. The data at the cursor position can be modified with the "increase" and "decrease" keys. Before the system is used, the parameters of each oil point must be set. The oil point number with the oil quantity of 0 is considered to be closed without oil supply.

Automatic operation: After starting the automatic operation, the system will automatically supply oil point by point according to the set parameters. Because the parameters of each oil point are not the same, the order of oil supply is not necessarily sequential. If no oil flow signal or communication error is detected during the oiling process, the system will briefly alarm and display the faulty oil point number, and the system will display the alarm fault point number cyclically during the interval. If the fault point has been eliminated at the next fueling, then The system no longer alarms and displays the original failure point. Automatic operation without manual guarding.

Manual control: In the manual control state, you can perform manual oiling on the oil point number on the current screen. As long as you press the "Start and Stop" key, the system will lubricate once according to the preset oil amount. You must press again after the oiling is completed. The "Start / Stop" key returns. The fuel point number is automatically increased and waiting for refueling.

Remote control: After the remote control instruction is executed, the system sends a ready signal to the central control room. After the remote control dry contact in the central control room is closed, the system enters the automatic operation state. If the remote drive is disconnected during the oil supply, the system will complete all points Then stop running, wait for the drive signal to close again and continue running.

The total number of flow controllers built into the display must match the total number of actual installations. Otherwise it will not run properly.

The electronic flow controller is composed of a valve body, a driving motor, a detection switch, and a control circuit.

The valve body is an assembly of volumetric oil supply body. It is driven by a DC motor. The piston in the valve body pushes a certain amount of lubricating oil in the cavity into the bearing under the pressure of the oil pressure. The number of piston operations is multiplied by each The amount of oil is the total amount of oil supplied. The number of times the piston is detected by the detection element can determine the amount of oil. If the oil circuit is blocked, the piston will not move. If the detection element does not detect an action signal, it will be regarded as a failure, and the control will fail. Call the police.

The electronic circuit is controlled by a single-chip microcomputer, which controls the work of the valve body and the data communication of the main controller. After receiving the refueling command of the main controller, the valve body is started to supply oil, and the oil supply status instruction is sent to the main controller after the oil supply is completed. The instruction includes fault information.

Each electronic flow controller has a fixed number. The numbers in the same system are in order and do not overlap. The numbers start from 0. For example, 000-2 means the second point of controller 0. Each number corresponds to each. Bearings.

The electronic flow controller is connected to AC26V power supply, communication lines A, B, PE, motor, and flow detection switch. According to the wiring diagram, the indicator light on the detection switch flashes normally when it is oiling, it does not flash as failure, and it is not oiling It may be on or off.

Do not enter rainwater and conductive dust or conductive gas in the electronic flow controller. Do not operate above 50 °.

The microcomputer controller in the intelligent lubrication electric control box is the core component of the lubrication system. It is connected to the lubrication pump, refueling pump, level switch, pressure switch, flow controller and DCS in the central control room. The system's lubricating and refueling pumps can be turned on automatically, stopped or manually. In automatic mode, it is controlled by the system, and the oil pump starts directly in the open position. The system has a serial bus communication port, which forms master and slave serial communication with various electronic flow controllers. Each electronic flow controller is controlled by the master controller to achieve timing and quantitative oil supply, fault alarm and other functions. The system is connected to the central control room of the user by DCS. The system provides signals to the central control room for operation, readiness, failure, and lubrication pump work, and the central control room can use a pair of dry contact signals to control the operation and stop of the lubrication system.

1.Home screen—automatic operation　　

The main screen and the auto run screen are combined into one screen. There are six buttons on the screen: auto run, manual run, reset stop, parameter setting, fault inquiry, and instructions. As long as you touch a button, the system will enter the function described by the button .

The automatic operation screen uses graphic animation to simulate the operating condition of the lubrication system to realize visual lubrication and intelligent lubrication.

As long as the power switch is turned on, the lubricating equipment will display the main screen of automatic operation, and the system will start automatic operation as soon as the automatic operation button is touched. On the automatic operation screen, there are graphics and data such as the fuel pump, lubrication pump, oil level gauge, pressure switch, oil pipeline supervisor, intelligent flow control distributor, fault display, alarm and so on. After the system is started, the lubrication pump starts to supply oil, and the lubricating oil in the oil pipe begins to flow. When the pressure switch is closed, the intelligent flow control distributor starts to supply oil. The number of the distributor and the point of oil being supplied are displayed in the graphics of the distributor. At the same time, the animation of the lubricant at the outlet of the dispenser is dripped onto the user's gear. If a certain point of failure does not occur, the alarm indicator lights up, and the alarm oil point number is displayed in the alarm data frame. The oil supply amount and interval time of each oil point is performed according to the set value. The system automatically performs the fuel supply according to the oil supply amount and interval time set by the user. If you want to stop the fuel supply, you can touch the stop button.

The system refuels the lubrication points point by point, and the pressure is concentrated to refuel quickly.

The system automatically recirculates the lubrication points without manual intervention.

2.Run manually
　　The graphic on the manual operation screen is the same as the automatic operation screen. First, manually start the lubrication pump, then enter the dispenser number and oil point number, and touch the manual refueling button to perform the refueling at this point. The fuel pump can also be started and stopped manually.

3.Run during interval
　　

After all the lubrication points are completed, the system enters the interval operation, shuts down the lubrication pump, displays the operation screen during the interval, and waits for the next lubrication. If the countdown period ends at a certain point, a new round of lubrication is started. The system works cyclically.

Fourth, parameter settings

On the parameter setting screen, first set the total number of distributors in the system, and then set the distributor number. Each distributor has 4 oil outlets. The oil quantity and interval of each oil point can be set independently. You can read the original data before setting. If the original data does not need to be changed, you can set the next distributor. The distributor number can be entered directly or you can set it gradually by pressing the "+-" key. Input data can touch the numbers in the data frame, and a soft keyboard will pop up automatically. Data can be entered and confirmed on the soft keyboard.

All oil point data must be saved after being set and will not be lost.

4.Fault information query
　　

In the fault information column, you can query the faulty oil point number and fault occurrence time, and you can also clear the fault information.

Pay special attention to setting the date and time after the system is powered on, otherwise the time when the fault occurs is different from the actual time.

The date and time of the system will disappear after power off, so please reset it after power on.

5.Instructions for use
　　There is a terminal block wiring diagram on the instruction screen.