The electrical control system of the electric grease machine integrates sensors, logic judgment modules, and actuators to construct a complete fault self-diagnosis and protection mechanism. Its core functions include real-time monitoring, anomaly identification, active protection, and fault recording to ensure stable operation of the equipment under complex working conditions.
The self-diagnostic function of the electrical control system relies on the real-time acquisition of key parameters by multiple types of sensors. For example, pressure sensors continuously monitor pressure changes in the lubrication pipeline, flow sensors record the grease delivery rate, temperature sensors track the operating temperature of the motor and pump, and level sensors report the remaining amount in the grease tank. These sensors convert physical signals into electrical signals, which are then transmitted to the central control unit for data analysis. When any parameter exceeds a preset safety range, the system immediately triggers an early warning mechanism, providing a basis for subsequent protection actions.
The logic judgment module is the core of the self-diagnostic system. It cross-validates sensor data using preset algorithms. For example, if the pressure sensor shows that the pipeline pressure remains below a threshold, the system will simultaneously check the flow sensor data: if the flow rate is normal, it may indicate a pipeline leak; if the flow rate is abnormal, it may indicate a pump malfunction or excessively high grease viscosity. Furthermore, the system integrates historical operating data to differentiate between intermittent and persistent faults, preventing false alarms caused by momentary interference. This multi-dimensional analysis ensures accurate fault location and provides targeted guidance for maintenance personnel.
Regarding protection functions, the electrical control system directly intervenes in equipment operation through control actuators. When a serious fault is detected, the system immediately cuts off the motor power to prevent the fault from escalating. For example, if the temperature sensor indicates motor overheating, the system will activate the cooling fan and reduce the operating frequency; if cooling is ineffective, it will force a shutdown and lock the start function until the temperature drops to a safe range. For faults such as pipe blockage or leakage, the system will close the solenoid valve of the corresponding branch to prevent grease waste or further equipment damage.
Fault recording and tracing functions are an important supplement to the electrical control system. The system's built-in storage module records the time, type, and key parameters of fault occurrences, forming a queryable fault log. Maintenance personnel can retrieve historical fault information through the human-machine interface or by connecting to a host computer software, analyze fault frequency patterns, and optimize equipment maintenance plans. For example, if a piece of equipment frequently experiences abnormal pressure, it may be necessary to inspect the pump seals or replace the high-viscosity grease to address the problem at its root.
The self-diagnostic and protection functions of the electrical control system are also reflected in its power quality monitoring. The system monitors the stability of the input voltage in real time. If voltage fluctuations exceed the allowable range, it will adjust the voltage through the voltage regulator module; if the voltage remains abnormal, it will activate the backup power supply or shutdown protection to prevent damage to the control unit due to power problems. In addition, the system has a grounding detection function to ensure a reliable connection between the equipment casing and the ground, preventing safety hazards caused by leakage.
The integration of communication interfaces further expands the functional boundaries of the electrical control system. Through RS485, CAN bus, or industrial Ethernet, the system can interact with a host computer or remote monitoring platform. Managers can view the equipment's operating status in real time from the central control room, receive fault warning information, and even remotely adjust control parameters. This remote management capability not only improves fault response speed but also reduces the manpower costs of on-site inspections.
The electrical control system of the electric grease machine constructs an efficient and reliable self-diagnosis and protection system through sensor networks, logic judgment algorithms, actuator linkage, and fault recording mechanisms. It can not only monitor the equipment's operating status in real time, quickly locate and handle faults, but also optimize maintenance strategies through data traceability, providing a solid guarantee for the long-term stable operation of the equipment.
