Features

1. Extended Equipment Life
By establishing a lubrication plan for timely and adequate supply, the system can extend the lifespan of the machinery.
2. Risk Prevention
The system automatically lubricates even during operation or in high-risk locations, helping to prevent accidents.
3. Improved Operating Rate
There is no need for downtime due to lubrication failure, which reduces machine breakdowns and the time needed for lubrication in hazardous areas.
4. Prevention of Lubrication Failure
Automation of lubrication helps prevent failures caused by intentional neglect or oversight in lubrication.
5. Cost Reduction in Lubrication Management
Using an automatic lubrication system reduces the need for manual lubrication personnel and minimizes losses caused by over-supply or under-supply of grease.
6. Prevention of Contamination by Foreign Materials
The grease is not exposed to the atmosphere, preventing degradation and contamination by foreign substances.
7. Power Saving
Reducing friction at bearings and contact surfaces results in energy savings.

Operating Principle

The grease stored in the grease tank is drawn into the pump and supplied to each distribution valve through the switching valve via the #1 supply line. When the grease reaches each distribution valve and pushes the supply valve down, it opens the passage to the piston. The grease is then pushed through this passage, allowing the grease stored beneath the piston to be supplied to the lubrication points through the supply chamber.At this time, the grease that was below the supply valve returns to the grease tank via the #2 supply line. Once this cycle is complete, there is a designated downtime before the pump operates again. When the pump activates, the switching valve opens in the opposite direction, functioning in reverse order to the previous operation.

Lubrication systems are categorized based on their drive method and piping method. Pumps, distribution valves, and auxiliary equipment are standardized according to their capacities, as outlined below.

• The above specifications are standard products and can be manufactured to a maximum pressure of 400 kgf/cm² upon request.
• If you intend to use it as an oil pump, please specify separately.
• The maximum number of lubrication points and piping lengths are based on NLGI #0 and DV-30 type and may vary depending on the surrounding environment and temperature.
• The voltage of the electric motor may also change based on the installation location.

Features

1. Suitable for machinery with concentrated lubrication points.

2. Low piping cost.

3. Provides reliable lubrication assurance.

4. Allows for continuous lubrication.

Applications

Small and medium industrial machines, machine tools, printing machines, transportation vehicles, etc.

Components

Features

1. Used for medium to small-scale applications with long lubrication intervals.

2. Cost-effective equipment.

3. Simple manufacturing process.

Applications

Steelmaking equipment, drawing equipment, cranes, etc.

Device Description

The grease pumped from Pump 1 is supplied to one of the two main lines by switching the manual changeover to LEVEL 2, with the other line being opened to the tank.When Distributor Valve 3 operates, the lubrication process is completed, and as the pressure rises to indicate the completion of lubrication, changing the changeover level position will direct the lubrication to the opposite line. At this time, the switching pressure must be noted.

Components

Features

1. Suitable for devices with relatively concentrated lubrication points in medium to small-scale applications.

2. Pressure adjustment at the pump facilitates maintenance and inspection.

Applications

Steelmaking equipment, transportation equipment, industrial machinery, etc.

Components

Features

1. Suitable for medium to large equipment with a relatively high concentration of lubrication points.

2. Reliable lubrication is possible by controlling the completion of lubrication by the pressure at the end of the piping.

Applications

Steelmaking equipment, paper machinery, transportation equipment, industrial machinery, etc.

Device Description

Pump goes through one of the two supply pipes and operates the distribution transformer via the electromagnetic switching valve (2), and when oiling is completed at each oiling point, the pressure increases and the pressure control valve (4) is activated. When the pressure rises and reaches the set pressure of the pressure control valve (4), it is switched off, sending a signal to the electric control panel, which switches the electronic control side in the opposite direction to receive the signal and stops the pump. When the set time elapses, the SYSTEM TIMER is activated and the reverse oil supply pipe is oiled.

Components

Features

1. Suitable for areas where lubrication points are generally concentrated.

2. Reliable operation as the discharged grease returns under pressure for switching.

Applications

Steelmaking equipment, etc.

Device Description

Grease pumped from the pump passes through one of the two supply lines via a hydraulic switching valve, activating the distribution valve. Once lubrication at each lubrication point is complete, the pressure rises, and when it exceeds the set pressure of the hydraulic switching valve, it automatically switches. At the same time, a switching signal is sent to the electrical control panel, stopping the pump. After a preset time has elapsed, the system timer activates, allowing lubrication through the opposite supply line.

Components

Features

1. Suitable for the appropriate quantity, pressure, and temperature of lubrication for various industrial equipment’s driving devices (bearing, gear parts, sliding parts).

2. This system is essential for cost reduction and extending the management lifespan of equipment.

Applications

Paper machines, drying machines, mining equipment, large reducers, rolling equipment, textile machinery, plastic processing machines, large blowers, etc.

Device Description

This is an oil circulation system designed for lubrication and cooling, which is one of the most critical components of paper manufacturing equipment. It continuously supplies the appropriate amount of lubrication to various lubrication points, such as the gear contact surfaces and bearing housings of the wet and dryer parts, as well as the dryer cylinder. The system returns the lubricating oil to the tank, maximizing lubrication management and the lifespan of the equipment.

External Drawing

Overview

The forced circulation lubrication device supplies optimal lubrication conditions, including the appropriate quantity, pressure, and temperature, to the driving components (bearing, gear, sliding parts) of various industrial equipment. Therefore, it is an essential device for managing equipment and extending its lifespan.Paper machines, Large reducers, Plastic processing machines, Drying machines, Large blowers, Mining equipment, Textile machinery

Piping Layout

Dryer section of paper machine

①Dryer -Roll
②Stretcher-Roll
③Canvas-Roll
④Pump Ass'y
⑤Sight Glass Pannel
⑥Line(Pipe)

- Includes driving components such as nozzles, gearboxes, and other parts tailored to the system.

To effectively function as a centralized lubrication system, it is essential to install the system based on the appropriate selection of equipment and suitable piping design.

Selection of Distribution Valves and Lubrication Flow Rate

The lubrication flow rate may vary depending on factors such as the size of the bearing, rotation speed, ambient temperature, load, and type of grease. The lubrication flow rate is generally calculated using standard formulas. Once the flow rate is determined, it is advisable to consider the lubrication intervals to decide the size of the distribution valves and adjust the discharge rates for each lubrication point.

Piping Materials

The piping materials should primarily consist of carbon steel pipes for pressure piping (STPG38, Sch. 80) or steel pipes.

Supply Line Pressure Loss and Lubrication Pipe Pressure Loss

The pressure loss of grease flowing through the pipes varies based on the flow rate per unit time, temperature, type of grease, and internal diameter of the pipe.

Pump Selection

The flow resistance of the GREASE is determined by factors such as the type of grease used, temperature, pipe length, and flow velocity. There are several methods for calculating flow resistance, but it is generally calculated using the Hagen-Poiseuille equation.

In calculating the apparent viscosity in equation (1), the shear rate is calculated using equation (2), and the value is obtained from the GREASE MAKER's data (shear rate - apparent viscosity chart). The shear rate - apparent viscosity chart varies depending on the GREASE brand, temperature, etc., so caution is required.

Pipe Flow Resistance Table

* The discharge pressure of the PUMP (a)
-Calculated with a maximum of 170 kgf/cm².
* The switching pressure (b)
- Set to 50 kgf/cm².
(When the distribution valve and pressure regulating valve are installed under the same conditions, and the pressure regulating valve is located near the PUMP, the maximum adjustment pressure of the pressure regulating valve must be set to 170 kgf/cm².)

P= Operating pressure of the distribution valve 30 kgf/cm² (PISTON pressure loss + supply line pressure loss + Bearing back pressure) + Safety pressure 20 kgf/cm² = 50 kgf/cm²
* In conditions other than (a) and (b), the pressure loss near the inlet of the distribution valve is designed to a maximum of 120 kgf/cm².

<<Conditions>> ① GREASE NLG1 #1(k company M GREASE)
② Temperature 0℃
③ Thickness of copper pipe Sch.80

Selection of Operating Time

When using the distribution valve as ARHI-DW, the discharge amount is calculated as 1/2. (In the case of an electric PUMP, if the pump's operating time is designed to be within 5 minutes according to the above calculation, stable operation can be achieved.)

1. Regular Inspection

The GREASE supply system needs to be inspected regularly. However, regular management tasks are usually unnecessary except for regular GREASE replenishment, GEAR BOX GREASE replacement, and checking for inadequate operating conditions.

1) Inspection of Series System

Since individual distribution valves do not have indicators, when one distribution valve operates, all distribution valves operate as well, requiring caution. However, since there are cases where one lubrication point or a group of lubrication points are bypassed, it is necessary to check each lubrication point individually.

2) Inspection of Parallel System

Usually, each distribution valve has an indicator rod, so it is essential to check whether each distribution valve operates during the lubrication cycle. If there is no indicator rod, it is necessary to check whether GREASE is discharged at each lubrication point. Additionally, records should be checked regarding the pressure reaching, the time taken to reach the specified pressure, and the time taken to complete a complete lubrication cycle. A low rate of pressure increase and significantly decreased maximum pressure may indicate air intrusion into the system, leakage, damage in the piping, or incomplete operation of the GREASE pump.

2. Adjustment of Lubrication Quantity and Selection of Distribution Valve, etc.

The amount of GREASE supplied to the sliding bearings is determined by factors such as the bearing spacing. Therefore, in the case of GREASE lubrication, it is principle to exchange 1/3 of the total volume of the bearing spacing every 4 hours. If the spacing increases due to wear, the lubrication quantity should be increased. Careless handling or supply operations of GREASE may lead to solids entering the GREASE tank. If this contaminated GREASE flows into the system, the system must be disassembled and each part cleaned. When replacing with a different type of GREASE, the system should be thoroughly cleaned, or the lubrication points should be opened, and the pump should be operated until new GREASE is discharged.

3. Dents and Damage to Piping

If the piping is dented, at least one lubrication point may malfunction, or pressure may increase excessively.

4. Air Intrusion

When supplying GREASE from above without using the supply port or using a supply pump, care must be taken to avoid air intrusion. If air is mixed in, the indicator rod may not operate, or there may be issues with pressure increase and pump startup. Therefore, air should be evacuated using a pump at appropriate locations, and air in the pump should be removed using the air vent on the pump body.

5. Foreign Substance Intrusion in the System

If foreign substances enter, they may hinder the operation of various valves, necessitating cleaning. To prevent this, always keep machinery and hands clean during contact.

6. Color Change Due to Separation of Soap Fraction

Using inadequate GREASE can cause the separation of oil and soap fractions, resulting in soap deposition, which necessitates cleaning.