In engines and industrial machinery, automatic lubrication systems (ALS), commonly referred to as centralized lubrication systems (CLS), are mechanical devices that administer predetermined amounts of lubricant to distribution points while the machine is running.
A reservoir with a pump, feed lines, metering valves, and injectors make up an automated lubrication system. Switches are used to link the automated lubrication system to a control system.
Either human input or computerization (also known as computer numerical control, or CNC) may be used in the control system.
In this article, we will explore what a automatic lubrication system is, it’s application, diagram, types, and how it works. We also discussed Lubricants for lubrication system, it importance, advantages, and disadvantages.
What Is Automatic Lubrication System?
When a machine is in operation, an Automatic Lubrication System (ALS), also known as a Centralized Lubrication System (CLS), distributes regulated quantities of lubricant to various parts of the machine.
A system that needs a human pump or button activation is nonetheless classified as a centralized lubrication system, even though these systems are often completely automated.
Reliance on limited skill can be decreased and machine availability can be increased with centralized automated lubrication systems. By applying the right amount of lubricant at the right times, these systems reduce wear and friction and prolong the life of bearings and equipment.
A vital component of maintenance and reliability programs are automatic lubrication systems. They deliver measured quantities of oil or grease to lubrication stations from a central place. The pump is supplied by a readily accessible reservoir and provides the system with the selected lubricant.
The reservoir might be as little as 2 liters or as large as an intermediate bulk container or even a bulk tank, depending on the purpose. The alternatives vary depending on the application and are nearly infinite.
These systems may be immediately connected to the PLC of your facility and can be remotely monitored with feedback. Therefore, you can be confident that your assets are always being adequately oiled, whether you’re operating an excavator, a ready-mix truck, a crusher, or a steel mill.
Applications
- Automatic lubrication are often used in automotive, food and beverage, mining, printing, packaging, steel, paper, and industrial machining.
- Dependent locations: power plants, oilfields, steel processing facilities.
- Used in residential homes for computer and car maintenance.
Two distinct categories can be used to classify the system, and many of their components may be similar.
- Oil systems: CNC milling and other stationary production equipment are the main applications for oil systems.
- Systems of grease: The main application for grease is on mobile equipment including trucks, mining, and construction machinery.
Importance Of Automatic lubrication System
For any spinning machinery to operate well and last a long time, lubrication is essential. Lubrication makes it easier for moving machine parts to glide past one another by lowering friction. Proper lubrication is arguably the most crucial aspect of industrial maintenance.
Many industrial and manufacturing processes would wear out more quickly without lubricating systems due to friction, overheating, and basic maintenance needs. (Industrial bearings seldom endure more than 10% of their potential life lifetime when left unlubricated.)
Continuously maintained machinery reduces overall commercial productivity and lengthens production downtime. According to some US-based estimates, improper lubrication is responsible for somewhat more than 50% of all industrial bearing failures.
Diagram
Types Of Automatic Lubrication System
Lubrication systems come in a broad range of configurations and applications, as was previously mentioned. The way a system operates determines one of the more practical ways to classify automated lubrication systems. There are several different types of automatic lubrication systems including:
Multi-point lubrication systems:
A distribution block is frequently used to identify multi-point lubrication systems. This block directs its output to a network of many hoses and connects to and receives input from a single lubricating unit. The distribution block’s hoses connect to various bearings and/or pieces of equipment.
There are several alternative lubrication methods. These consist of recirculating oil lubricating systems, single line resistance lubricating systems, mist lubrication systems, minute volume/low pressure spray systems, multi-port direct lubricating systems, and others.
Automatic Lubrication system:
Automatic lubrication systems can occasionally be identified by the particular lubrication applications for which they are intended. Chain oilers, air lubricators, gas pumps, chain spray/brush lubricating systems, and constant level oilers are a few examples of these systems. Chain oilers are made to operate on chains or rails.
Conversely, air lubricators provide compressed airlines both lubrication and filtration. Although they can be put outside of the air system, they are typically integrated within the airline itself, where they can continuously lubricate all of its internal mechanisms.
Chain spray/brush lubricating systems are used in oven applications in the food processing sector, whereas gas pump lubricators are intended to prevent fuel pumps from drying out, which can result in irreversible damage. Lastly, the fluid level in various types of equipment is maintained by constant level oilers.
They specifically aid in preventing excessive moisture loss and friction in pillow blocks, pump housings, gearboxes, and bearings. (Although it is not the subject of this article, it is worth mentioning that internal combustion engines depend on automated lubrication systems that use force-feed or pressure-feed, occasionally with the assistance of an auxiliary pump.)
Parallel lubrication systems:
The use of numerous, parallel systems of injectors or valves distinguishes parallel lubrication systems from single progressive systems. Each injector is limited to a single lubricant administration point, in contrast to a single progressive system. There are two types of parallel lubrication systems: single-line parallel and double-line (or dual-line) parallel.
During the lubrication process, pressurized lubricant is vented back to the reservoir in both kinds of systems. (Double line parallels achieve this by using a second supply line, whereas single line parallels do this by turning off the pump.)
Double-line parallel lubricating systems differ from single-line systems primarily because the latter have reversing valves that enable pumps to pressurize the second supply line while lubricating.
Single Line Parallel systems:
The way oil gradually moves between a series of metering valves is the source of the term for single line progressive lubrication systems. The lubrication process in this kind of system is started by the pump delivering a single lubricant shot.
Before moving on to the next valve, a sequence of valves or pistons gradually redirects oil to bearings or other application locations. Eventually, the advancement is stopped by some kind of timed feedback system.
Single-line progressive system:
A single-line progressive system cycles individual metering valves and valve assemblies by using the lubricant’s natural flow. In a cylinder with a certain diameter (bore), the valve’s cycling causes the pistons to move back and forth.
Lubricant is displaced as a piston advances, which pushes the subsequent piston to advance as well. Although the valve output has a constant volume, the time it takes for each piston to travel back and forth may be preprogrammed and changed. The points for lubrication are grouped in series.
Dual-line parallel system:
Additionally, a dual-line parallel system applies lubrication in measured quantities using hydraulic pressure. One line builds hydraulic pressure while the other vents pressure in an alternating manner.
With a single pump and feed lines of comparatively modest diameter, the dual-line parallel system may lubricate hundreds of lubricant distribution points spread over thousands of feet.
How Does An Automatic Lubrication System Works
An automatic lubrication system can lubricate multiple machine parts at once. (Even though they are automated, some ALS systems might need to be started by pressing an activation button or manually pumping.)
The compatibility and configuration of automatic lubrication systems vary greatly. A controller/timer, a pump, a supply line, metering valves/injectors, and feed lines are the five main parts that they all have in common.
- The lubrication system is turned on and off by the controller, also known as the timer, which can be operated from inside the pump or outside.
- The pump is in charge of moving lubricant from the reservoir—where it is kept—into the main system.
- The lubricant can reach the metering valves and injectors thanks to the supply line, which is connected to the pump.
- The lubricant must be measured by the metering valves, also known as injectors, before being dispensed into the feed lines.
- The lubricant is ultimately delivered to its designated application points via the feed lines.
Lubricants For Automatic Lubrication System
Solids, solid/liquid dispersions, liquids, greases, and gases are all possible forms of lubricants. The most crucial aspect of any lubricant is its viscosity, which is defined as a substance’s capacity to withstand flow when subjected to force.
One significant, secondary feature of any lubricant is the thickness of the specific material. Lubricating systems often employ grease or oil. Oil has a relatively high viscosity and does not stick to surfaces, making it a great lubricant.
Mineral oils, such as petroleum, are ideal for lubricant applications because they have a far longer resistance to degeneration than organic oils. Even more viscous than oil, grease is a semisolid. The type of grease derived from animal fat is not used in industrial settings for lubrication.
Instead, it combines mineral or vegetable oil with soap. Grease containing synthetic oils, such as silicones, hydrogenated polyolefins, fluorocarbons, and esters, is increasingly used in industrial lubrication.
The cost of synthetic oils and their wider variety of viscosities, consistencies, and environmental effects are the main reasons for this shift to synthetic grease. Because grease lasts longer and requires less maintenance, it is typically used on parts that need less lubrication.
Advantages Of An Automatic Lubrication System
- It is a proven technique with a dependable distribution of lubrication to every place when the machine is in operation
- The system improve performance and up-time by getting more operational time each day and spending less time on maintenance
- It also maximize equipment life and assist to minimize unanticipated equipment shutdowns, expensive repairs, and unscheduled downtime
- automatic lubrication protect important equipment with modern monitoring systems that notify of problems before disasters occur
- it create a safer work environment for maintenance people
- The system eliminate the faults and infrequency that occurs with manual application of grease
- The system is engineered to tolerate severe settings
- Environmentally beneficial by decreasing oil usage and grease waste
- Suitable for various applications
Disadvantages Of An Automatic Lubrication System
Excessive Lubrication and its Environmental Impact
- The lubrication system is excessive lubrication can lead to environmental costs, including spills and financial penalties for unintentional leaks.
- It can cause non-availability of critical machines, increasing indirect costs.
- It is excessive lubrication increases the risk of leaks, necessitating replacement of parts like hoses, air filters, vents, seals, etc.
- Over-lubrication can cause a machine’s tribological conditions to change, increasing energy costs.
- The excessive lubricant can collect environmental dirt, affecting the system’s overall performance.
- The changes in lubricant amount can cause temperature rise, altering lubrication conditions, and causing abnormal wear and accelerated oxidation.
- Its excessive lubrication can also damage joints, causing seals to degrade and shatter, allowing water and dirt to enter the mechanical system.
FAQs
How do automatic lubrication systems work?
By lubricating constantly while the machine is operating, an automated lubrication system (ALS) optimizes lubricant distribution and boosts efficiency by eliminating the need to halt machinery for lubrication.
What are the 7 steps of lubrication?
Seven Easy Steps for Grease Lubrication
- Select the Proper Grease.
- Find out how and where to apply.
- Decide on the ideal frequency.
- Check the effectiveness of the lubrication.
- Make Use of the Correct Grease Sampling Method.
- Select the Proper Test Slate.
- Apply the lessons you’ve learned.
What is the automatic lubrication system ALS?
Centralized lubrication systems (CLS), another name for automatic lubrication systems (ALS), are mechanical devices that are used in engines and industrial machinery to distribute predetermined amounts of lubricant to distribution points while the machine is running.
What are the 4 types of lubricants?
Oil, grease, penetrating lubricants, and dry lubricants are the four different types of lubricants. Your facility will continue to use dry and penetrating lubricants, but the two most frequent lubricants you will encounter on a regular basis are oil and grease.