Understanding the benefits of the automatic lubrication system (PART 2).
The "PART 1", was mainly about the benefits of using a lubrication system. In this second part, we will rather analyze the purchasing process and focus on the essential questions to ask in order to obtain the system that meets you.
Let's start by asking ourselves the question: What is an automatic lubrication system?
The automatic lubrication system generally consists of five main components:
- Controller/timer – activates the system.
- Pump and reservoir – stores and supplies the lubricant to the system.
- Supply line - the line (generally of 3x thickness of polyurethane) in which the lubricant is transferred from the pump to the distribution valves.
- Distribution valves - component that measures/distributes the lubricant to the lubrication points.
- Supply lines – lines that are linked to the distribution valves to the lubrication points (generally in steel, polyurethane or polyamide).
Operation starts once the controller/timer sends a signal to the pump to start a lubrication cycle. The pump automatically delivers lubricant through the intermediate supply line to the distribution valves which measures and distributes a predetermined amount via a secondary supply line to the lubrication points.
Purchasing a system:
When purchasing a system, make sure to ask the right questions, in order to have the system that meet your needs
The first thing you need to know is that there exists different principals of function in which the automatic lubrication systems are designed. The two most common used on mobile equipment is progressive and parallel.
For a progressive system, a pump delivers grease to the greasing points via progressive distribution valves. The grease flows through a primary distribution valve which redirects towards secondary valves and finally through supply lines towards the lubrication points. The nature of the system is that if a line/a bearing does not take grease, the whole system stops and there are (in a system that is designed properly) a visual indication that there is a problem. This permits the operator to inform the foreman that there is a problem.
For a parallel system, the grease is pumped through single supply line towards many injectors. The injectors operate simultaneously but are independent from one to the other. Each injector serves as a greasing point and can be adjusted to supply the precise quantity of grease or oil. On a parallel system, the only pressure observed is on the main line so if there is a supply line or bearing that is not taking grease, the rest of the system will continue to function normally, but the bearings that do not receive grease will be damaged in the long term if the operator does not resolve the problem.
Once you decided on the type of system you want, here are other questions you could ask:
1. Does the pump consist of a high pressure grease filter for filling?
The filter prevents contaminants to enter the pump that could cause breakdowns, replacements parts and labor costs. This option is not standard – It needs to be requested. This type of filling option is done via the base by a barrel pump.
2. Does the system have a pressure gauge (electric pressure switch)?
A gauge permits the surveillance of the pressure in the system. It is always a standard option.
3. Does the system have a low level sensor?
This device sends a signal to the operator when the reservoir is empty, it also prevents to the pump to send air in the supply lines that can create many problems and a service call. This Is an option and needs to be requested.
4. Are the distribution valves equipped with grease nipples to permit greasing manually in case of an automatic lubrication system breakdown?
The fact of having a grease nipple on every distribution valve permits to easily lubricate manually, the verification of the system in manual and to bleed the system when necessary. When there is a service call on a system not equipped with grease nipples on the distribution valves, the lines have to be disconnected to perform numerous tasks which increases tremendously the labor costs.
On a parallel type of system, the injectors function independently from one another and the pressure is only controlled on the main line which means there is no indication (related to pressure) on each secondary supply line or bearing that does not receive grease, the only visual indication of the level of grease missing to a point is dependent of the operator.
5. Does the system require a special grease?
The system generally used for on road vehicles has a maximum low pressure switch with a pipe/tube of a small diameter and can only push the grease of grade 000 to 0 (honey like consistency).If the temperatures drop to -10C, The ‘’0’’ type grease becomes too difficult to pump and a thinner grease needs to be used. In warmer climates, less thick grease will drain, causing potential damages to the bearings and environmental problems. Systems with higher maximal pressure function’s (Progressive) take type 000 and EP2 grease. In addition some manufacturers require that you use a moly grease to ensure the operation. Others have no restrictions on the make and type of grease, which permits you to use your standard grease and considerably reduces stock and costs.
6. Is the system equipped with reusable fittings and not a pressed hydraulic hose?
This type of fitting permits for a quick repair, wherever the machine is located. It consists of having stock of fittings and hoses on hand in order to repair quickly.
7. Are they compression fittings on the lubrication points?
Many systems during installations use ‘’push-lock’’ fittings. This type of fitting costs less and is commonly used in pneumatic. It does not do the job on hydraulic, in the long term it will leak and will have to be replaced A compression fitting once installed could be good for the entire lifespan of the machine unless it’s damaged or ripped off.
In conclusion
Successful businesses are constantly seeking new solutions and technologies to reduce costs, minimizing down time and maximizing productivity. Could automatic lubrication be a solution?
An automatic lubrication system is an important tool to reduce direct and indirect costs resulting from improper greasing but you had to know how it functions and what are the available types of systems and which type would better meet your company’s needs. When purchasing an automatic lubrication system, ask the questions that were written in this article and you will obtain a tool which will maintain your machine, reduce costs and increase productivity with the years to come.