Automatic lubrication system
Encyclopedia
An Automatic Lubrication System (ALS), often referred to as a Centralized Lubrication System, generally comprises a controller or timer, a pump
and reservoir
, metering valves and fittings and supply and feed line
s. It typically delivers a controlled amount of lubricant
(either grease
or oil
) to multiple, specific locations on a machine while the machine is operating, at specific times from a central location.
s, mining
or construction equipment
, applying lubricant is often most effective when it is dispensed in small, measured amounts over short, frequent time intervals. However, time and human resource constraints or sometimes the physical location or type of machine often makes this approach to lubrication impossible. As a result, production cycles, machine availability, and manpower availability dictate the intervals at which machinery is lubricated which is not optimal for the point requiring lubrication. Auto lube systems are installed on machinery to address this problem.
The 3 most commonly used Automatic Lubrication System types are:
Operation begins when the controller/timer sends a signal to the pump to start the lube event. The pump then feeds lubricant into the supply line which connects to the primary metering valve, for either a preprogrammed amount of time or number of times as monitored through a designated piston cycle switch. Lubricant is fed to the multiple lubrication points one after another via secondary progressive metering valves sized for each series of lubrication points, and then directly to each point via the feed lines.
(now known as Lincoln Industrial) in the U.S.A.
A single line parallel system can service a single machine, different zones on a single machine or even several separate machines and is ideal when the volume of lubricant varies for each point. In this type of system, a central pump station automatically delivers lubricant through a single supply line to multiple branches of injector
s. Each injector serves a single lubrication point, operates independently and may be individually adjusted to deliver the desired amount of lubricant.
Operation begins when the controller/timer sends a signal to the pump starting the lube cycle. The pump begins pumping lubricant to build up pressure in the supply line connecting the pump to the injectors. Once the required pressure is reached, the lube injectors dispense a predetermined amount of lubricant to the lubrication points via feed lines.
Once the entire system reaches the required pressure, a pressure switch sends a signal to the controller indicating that grease has cycled through to all the distribution points. The pump shuts off. Pressure is vented out of the system and grease in the line is redirected back to the pump reservoir, until the normal system pressure level is restored.
Operation begins when the controller/timer sends a signal to the pump to start the lubrication cycle. The pump begins pumping lubricant to build up pressure in the first (the pressure) supply line while simultaneously venting the second (vent) return line. Once the required pressure is reached, a predetermined amount of lubricant is dispensed by the metering devices to half of the lubrication points via feed lines.
Once the pressure switch monitoring main supply line pressure indicates a preset pressure in the line has been reached, the system is hydraulically closed. The controller shuts off the pump and signals a changeover valve to redirect lubricant to the second main supply line.
The next time the controller activates the system, the second main line now becomes the pressure line while the first line becomes the vent line. The second line is pressurized and the entire process is repeated lubricating the remaining lube points.
Pump
A pump is a device used to move fluids, such as liquids, gases or slurries.A pump displaces a volume by physical or mechanical action. Pumps fall into three major groups: direct lift, displacement, and gravity pumps...
and reservoir
Reservoir
A reservoir , artificial lake or dam is used to store water.Reservoirs may be created in river valleys by the construction of a dam or may be built by excavation in the ground or by conventional construction techniques such as brickwork or cast concrete.The term reservoir may also be used to...
, metering valves and fittings and supply and feed line
Feed line
In a radio antenna, the feed line is the cable or other transmission line that connects the antenna with the radio transmitter or receiver. In a transmitter, it feeds the radio frequency current from the transmitter to the antenna, where it is radiated as radio waves. In a receiver it transfers...
s. It typically delivers a controlled amount of lubricant
Lubricant
A lubricant is a substance introduced to reduce friction between moving surfaces. It may also have the function of transporting foreign particles and of distributing heat...
(either grease
Grease (lubricant)
The term grease is used to describe semisolid lubricants. Although the word grease is also used to describe rendered fat of animals, in the context of lubrication, grease typically applies to a material consisting of a soap emulsified with mineral or vegetable oil...
or oil
Oil
An oil is any substance that is liquid at ambient temperatures and does not mix with water but may mix with other oils and organic solvents. This general definition includes vegetable oils, volatile essential oils, petrochemical oils, and synthetic oils....
) to multiple, specific locations on a machine while the machine is operating, at specific times from a central location.
Reason for an Automatic Lubrication System
Whether the equipment is stationary, such as in a manufacturing facility or mobile such as truckTruck
A truck or lorry is a motor vehicle designed to transport cargo. Trucks vary greatly in size, power, and configuration, with the smallest being mechanically similar to an automobile...
s, mining
Mining
Mining is the extraction of valuable minerals or other geological materials from the earth, from an ore body, vein or seam. The term also includes the removal of soil. Materials recovered by mining include base metals, precious metals, iron, uranium, coal, diamonds, limestone, oil shale, rock...
or construction equipment
Construction Equipment
Construction Equipment is a trade publication and web site serving the information needs of construction contractors, materials producers, and other owners and operators of construction equipment....
, applying lubricant is often most effective when it is dispensed in small, measured amounts over short, frequent time intervals. However, time and human resource constraints or sometimes the physical location or type of machine often makes this approach to lubrication impossible. As a result, production cycles, machine availability, and manpower availability dictate the intervals at which machinery is lubricated which is not optimal for the point requiring lubrication. Auto lube systems are installed on machinery to address this problem.
Benefits of an Automatic Lubrication System
Auto lube systems have many advantages over traditional methods of manual lubrication:- All critical components are lubricated, regardless of location or ease of access
- Lubrication occurs while the machinery is in operation causing the lubricant to be equally distributed within the bearingBearing (mechanical)A bearing is a device to allow constrained relative motion between two or more parts, typically rotation or linear movement. Bearings may be classified broadly according to the motions they allow and according to their principle of operation as well as by the directions of applied loads they can...
and increasing the machine’s availability. - Proper lubrication of critical components ensures safe operation of the machinery.
- Less wearWearIn materials science, wear is erosion or sideways displacement of material from its "derivative" and original position on a solid surface performed by the action of another surface....
on the components means extended component life, fewer breakdownsBreakdown (vehicle)A vehicle breakdown is the operational failure of a motor vehicle in such a way that the underlying problem prevents the vehicle from being operated at all, or impedes the vehicle's operation so much, that it is very difficult or nearly impossible, or dangerous to operate, or else at risk of...
, reduced downtimeDowntimeThe term downtime is used to refer to periods when a system is unavailable.Downtime or outage duration refers to a period of time that a system fails to provide or perform its primary function...
, reduced replacement costs and reduced maintenance costs - Measured lubrication amounts means no wasted lubricant
- Safety - no climbing around machinery or inaccessible areas (gases, exhaustExhaust gasExhaust gas or flue gas is emitted as a result of the combustion of fuels such as natural gas, gasoline/petrol, diesel fuel, fuel oil or coal. According to the type of engine, it is discharged into the atmosphere through an exhaust pipe, flue gas stack or propelling nozzle.It often disperses...
, confined spaces, etc.) - Lower energy consumption due to less frictionFrictionFriction is the force resisting the relative motion of solid surfaces, fluid layers, and/or material elements sliding against each other. There are several types of friction:...
- Increased overall productivity resulting from increase in machine availability and reduction in downtime due to breakdowns or general maintenance
Five Main Components of an Automatic Lubrication System
Regardless of the manufacturer or type of system, all automatic lubrication systems share 5 main components:- Controller/Timer – what activates the system
- Pump & Reservoir – stores and provides the lubricant to the system
- Supply Line – line that connects the pump to the metering valves or injectors. The lubricant is pumped through this.
- Metering Valves/Injectors– component that measures/dispenses the lubricant to the application points.
- Feed lines - line that connects the metering valves or injectors to the application points. The lubricant is pumped through this.
Different Types of Automatic Lubrication Systems
There are several different types of automatic lubrication systems including:- Single Line Parallel systems
- Dual Line Parallel systems
- Single Point Automatics
- Single Line Progressive systems (or Series Progressive)
- Single Line Resistance
- Oil Mist and Air-Oil systems
- Oil re-circulating
- Chain lube systems
The 3 most commonly used Automatic Lubrication System types are:
- Single Line Parallel,
- Dual Line Parallel and
- Single Line Progressive.
Single Line Progressive
A single line progressive system uses lubricant flow to cycle individual metering valves and valve assemblies. The valves consist of dispensing pistons moving back and forth in a specific bore. Each piston depends on flow from the previous piston to shift and displace lubricant. If one piston doesn’t shift, none of the following pistons will shift. Valve output is not adjustable.Operation begins when the controller/timer sends a signal to the pump to start the lube event. The pump then feeds lubricant into the supply line which connects to the primary metering valve, for either a preprogrammed amount of time or number of times as monitored through a designated piston cycle switch. Lubricant is fed to the multiple lubrication points one after another via secondary progressive metering valves sized for each series of lubrication points, and then directly to each point via the feed lines.
Single Line Parallel
The first single-line parallel system for industry was introduced in 1937 by Lincoln EngineeringLincoln Industrial Corporation
Lincoln Industrial Corporation is a manufacturer of automated lubrication systems, manual lubrication equipment and industrial pumping systems...
(now known as Lincoln Industrial) in the U.S.A.
A single line parallel system can service a single machine, different zones on a single machine or even several separate machines and is ideal when the volume of lubricant varies for each point. In this type of system, a central pump station automatically delivers lubricant through a single supply line to multiple branches of injector
Injector
ʎ̩An injector, ejector, steam ejector, steam injector, eductor-jet pump or thermocompressor is a pump-like device that uses the Venturi effect of a converging-diverging nozzle to convert the pressure energy of a motive fluid to velocity energy which creates a low pressure zone that dɯaws in and...
s. Each injector serves a single lubrication point, operates independently and may be individually adjusted to deliver the desired amount of lubricant.
Operation begins when the controller/timer sends a signal to the pump starting the lube cycle. The pump begins pumping lubricant to build up pressure in the supply line connecting the pump to the injectors. Once the required pressure is reached, the lube injectors dispense a predetermined amount of lubricant to the lubrication points via feed lines.
Once the entire system reaches the required pressure, a pressure switch sends a signal to the controller indicating that grease has cycled through to all the distribution points. The pump shuts off. Pressure is vented out of the system and grease in the line is redirected back to the pump reservoir, until the normal system pressure level is restored.
Dual Line Parallel
A dual line parallel system is similar to the single line parallel system in that it uses hydraulic pressure to cycle adjustable valves to dispense measured shots of lubricant. It has 2 main supply lines which are alternatively used as pressure / vent lines. The advantage of a two-line system is that it can handle hundreds of lubrication points from a single pump station over several thousand feet using significantly smaller tubing or pipe.Operation begins when the controller/timer sends a signal to the pump to start the lubrication cycle. The pump begins pumping lubricant to build up pressure in the first (the pressure) supply line while simultaneously venting the second (vent) return line. Once the required pressure is reached, a predetermined amount of lubricant is dispensed by the metering devices to half of the lubrication points via feed lines.
Once the pressure switch monitoring main supply line pressure indicates a preset pressure in the line has been reached, the system is hydraulically closed. The controller shuts off the pump and signals a changeover valve to redirect lubricant to the second main supply line.
The next time the controller activates the system, the second main line now becomes the pressure line while the first line becomes the vent line. The second line is pressurized and the entire process is repeated lubricating the remaining lube points.