Lubrication system / lubrication installation

Lubrication system / lubrication installation

lubrication system is quite a broad term used to describe that greases and oils have to be distributed in the way so that all connected bearings are supplied with the correct quantity of lubricant. In the distribution of various media, it centers on this economical, fast, safe and environmentally friendly transport from one container to the lubrication point. In the distribution of various media, it centers on this economical, fast, safe and environmentally friendly transport from one container to the lubrication point.

The lubrication system can be planned as electric, manual, pneumatic or hydraulic system. 
The first step for planning a lubrication system is to calculate the needed length of pipe and the necessary grease quantity. Only a process engineer is enabled to  plan and calculate the individual line resistances. The sum of the single line resistances is called the back-pressure which is crucial for the system design.
If there is too much resistance in the line system and the couplings and the distributors, the pump is forced to set up such a high pressure in the lubricating system so that the individual components in such a lubrication system can get to the nominal load limits. In case of an overpressure a safety valve opens, depending on the system manufacturer.

An example:
A line distance of 10 meters with an inner tube diameter of 4 mm and the use of grease class 2, there will already result a differential pressure of 60 bar. The pump has to compensate this pressure in the lubrication system. If the initial pressure of the pump in the lubrication system let run a overpressure valve at the pressure level of 250 bar, please calculate as follows:

250 bar initial pressure minus the differential pressure of the pipeline system and the resistance of the different couplings and distributor result in the inlet pressure at the lubrication point of the lubricating system.
An elbow screw fitting in the lubrication system has always an inside  angle of 90° or a 90 degree arc. With a 90 degree angle fitting, the differential pressure of the lubrication system which is equipped with these glands, has always a three times higher resistance , which the grease/ Lubricant has to overcome. A lubrication system, equipped with a 90° angle fitting, It should be noted that different configurations of the fittings and hose lines of the lubrication system generate different differential pressures. With the use of distributors is important to note that progressive distributor  have a resistance of 15 to 60 bar. Progressive distributor (distributor plate or block distribution) operate in a lubricating system as a mechanical distribution station for grease and oils. The distributors are driven by the initial pressure of the pump and distribute the grease, driven by several piston of different design, direction of the lubrication point or subsequent line of a lubricating system.
The distributors are used in lubrication systems, both in the in commercial vehicle lubrication as well as in industrial lubrication. This use of distributors has the advantage that it can control the grease quantity, a safe grease flow and the function can be monitored. These lubrication systems are driven by a piston pump and supply systems with 5, 60 or even a few 100 lubrication points. The filling of this piston pump at a lubrication system is carried out by the grease gun, a filling cylinder or an air pressure lubrication device or a pneumatic or manual filling pump.

The use of greases up to class NLGI 2 with progressive lubrication systems, has the advantage to avoid any contamination of the lubricating point or bearing point. The time-controlled pump works with time-intervals, controlling duration and break-times. The pulse managed pump allows the operator to lead to the right grease quantity to the lubrication point. In case of over-greasing, just change the intervals directly at the pump. This is very easy to do, even by non-trained workers.
The final assessment of the benefits of a lubrication system is subject to the local user. The advantages are solely for financial reasons. The lubrication systems on commercial vehicles or construction vehicles are subject to strong pressures by different users, applications, and the local conditions. But the robust design of a lubrication system will work in practice, so that you convince a customer of the benefits of such a system very easily.
 

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