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Precision Lubrication at Its Best: Understanding Automatic Lubrication Management Systems


Precision Lubrication at Its Best: Understanding Automatic Lubrication Management Systems

Precision Lubrication at Its Best: Understanding Automatic Lubrication Management Systems

Proper lubrication plays a critical role in the smooth functioning and longevity of machinery and equipment across various industries. 

Traditionally, manual lubrication has been the norm, but with advancements in technology, automatic lubrication management systems have emerged as a game-changer. These systems offer numerous advantages that significantly improve maintenance practices, enhance equipment performance, and optimise overall operational efficiency. 

In this blog, Catmacs Automated Lubrication will explore the key benefits of automatic lubricators and why they are becoming indispensable assets for modern industries.

Causes of Premature Bearing Failure

  • 50% Insufficient Re-lubrication
  • 15% Solid or Liquid Contamination
  • 10% Uncontrolled Re-lubrication Time Schedule
  • 10% Inappropriate Bearing Fittings
  • 10% Incorrect Maintenance
  • 5% Unsuitable Lubricant

Most grease-lubricated bearings fail to reach their life expectancy. The reason is that the re-lubrication procedure may be unclear or hard to follow. 

MQL (Minimum Quantity Lubrication) formulation has proven processes and procedures in providing the correct "Grease Volume" and "Re-Lubrication Interval" for optimising bearing reliability. Unfortunately, maintenance technicians still do not realise this issue, leading to poor control in greasing pressure over or under-lubrication.

Proper lubrication is crucial because under-lubrication will cause a premature bearing's failure. On the other hand, over-greasing will lead to catastrophic failure of the bearing (grease churning and overheating), eventually damaging the electromotor coils and windings.

The Advantages of Automatic Lubrication Systems

Enhanced Equipment Reliability

  • Consistent and precise lubrication
  • Automatic delivery of optimal lubricant amounts
  • Minimised wear, reduced breakdown risk, enhanced reliability

Increased Worker Safety

  • Elimination of manual lubrication in hazardous scenarios
  • Prevention of accidents and injuries
  • Safer working environment for maintenance personnel

Extended Machinery Lifespan

  • Proper lubrication for preserving machinery integrity
  • Timely application of lubricant to critical points
  • Reduced friction, prevention of premature wear, longer lifespan

Improved Maintenance Efficiency

  • Time-saving and efficient maintenance process
  • Continuous lubrication during operation, no interruptions
  • Streamlined maintenance schedules, consistent practices

Cost Savings in the Long Run

  • Initial investment offset by long-term cost savings
  • Precise lubrication reduces wastage
  • Extended equipment lifespan lowers maintenance and replacement costs
  • Enhanced reliability and reduced downtime lead to higher productivity

Introducing Comprehensive Solutions

Easylube Single-Point Automatic Lubricators

Engineered for Minimum Quantity Lubrication (MQL), this maintenance-free and user-friendly device stands as an embodiment of reliability. It ensures the seamless functioning of bearings, regardless of weather conditions, operational requirements, or harsh environments.

The Easylube single-point lubricator offers adjustable dispense settings spanning 1 to 12 months. It maintains minimum lubrication pressure to sustain grease quality and prevent oil seal failure. The patented infra-red control system provides round-the-clock monitoring, identifying feed blockages with LED warning lights and facilitating immediate corrective measures.

Economical Transition

Expendable materials are realised through the cost-effective replaceable grease cup and battery. Easylube lubricator boasts an operational life exceeding five years, ensuring stability, reliability, and suitability for diverse applications, particularly for hard-to-reach or hazardous locations.

Optimised product performance, reduced grease consumption, contamination prevention, and swift returns on investment are achieved by employing recommended accessories.

Easylube RFID Tag

Most grease-lubricated points benefit from being tagged with an "RFID tag" for Patrol Monitoring. This enhances the efficient management of each lubrication point in alignment with MQL demand.

Routine inspections aim to rigorously assess grease distribution on-site, aligning with the system's predetermined dispensing rate over a quantified period. Maintenance technicians adopt the "Listen, Feel, and Look" approach to identify irregularities, a pivotal aspect of preventive lubrication maintenance.

The "RFID tags" can be read by NFC-enabled devices, such as handheld PDAs or smartphones. Easylube's Guardwatch program operates seamlessly within this system, bolstering both patrol servicing and condition monitoring management.

Easylube Guardwatch

The Guardwatch patrol system empowers maintenance teams with five distinct work order assignments: Routine inspection patrol, replacement, troubleshooting, error reporting, system suspension, or restart. Displayed in the interface, these assignments simplify on-site missions for the maintenance team.

Guardwatch offers mobile communication via NFC-enabled devices, facilitating technicians' access to real-time work orders. They download assignments and upload mission reports to the PMS, ensuring prompt handling, identification, and recording of lubrication-related issues. This translates to optimal bearing performance, enhanced greasing precision, and effective routine inspections.

Easylube: A Seamless Solution for Every Location

Dispense Time Setting

MQL calculations determine the re-greasing interval and grease volume for each bearing based on actual operating conditions and OEM baseline.

To avert premature bearing failure, begin by configuring the dispense time setting of the Easylube single-point automatic lubricator according to each bearing's MQL formulation. Then, employ tags on Easylube PMS and Guardwatch to monitor and manage lube point statuses during routine inspections.

If you want more tips about choosing the right lubrication system, visit Catmacs Automated Lubrication’s business page by clicking here.

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