Automatic Lubrication Systems: Smart Solutions to Increase Efficiency

Automatic Lubrication Systems: Smart Solutions to Increase Efficiency

Automatic Lubrication Systems: Smart Solutions to Increase Efficiency

1. Introduction: The Importance of Lubrication in Industry

One of the most critical elements in the operation of industrial machinery is correct and regular lubrication. Lubrication is necessary to prevent frictional wear of moving parts, reduce heating and increase energy efficiency. However, manual lubrication methods require both labor and negatively affect system performance due to irregular lubrication. For this reason, automatic lubrication systems offer a great advantage in optimizing maintenance processes and extending equipment life.

2. What is an Automatic Lubrication System?

Automatic lubrication system is an integrated system that allows a specified amount of oil or grease to be automatically delivered to the areas needed by the machine at certain intervals. These systems usually consist of a central pump, distribution blocks, piping systems and control units. The system included in the PDF has been developed specifically for heavy-duty applications, providing high-performance, timed and pressure-controlled lubrication.

3. Working Principle of the System

1. The pump unit delivers oil or grease to the distributors in the system.
2. Proportional dispersive blocks direct this oil to the lubrication points in fixed quantities.
3. The oil  reaches the surface of moving parts such as bearings, linear guides, chains through the piping system.
4. The lubrication process  is repeated automatically with either a time-controlled or pressure-sensitive system.

4. Main System Components
5. Pump Unit

• Pump Type: Electric piston pump
• Oil Compatibility: Compatible with NLGI 000–2 class greases
• Pressure Rating: Maximum 280 bar
• Oil Reservoir: Capacities ranging from 3-8 liters

1. Distribution Unit

• Type: Proportional type dispenser block
• Material: High pressure resistant special alloy steel
• Number of Outputs: 2 to 12 output options
• Flow Value: Adjustable between 0.05 cm³ – 1.2 cm³

1. Control Unit

• Operating mode: Time-controlled or pressure-sensitive
• Integration: Compatible with PLC and machine control systems

1. Piping System

• Types: Steel pipe, high pressure hose or plastic pipe
• Connection: Push-in or tapered fittings option

5. Technical Specification Table

Characteristic	Value / Description
Maximum Working Pressure	280 bar
Oil Viscosity Compatibility	50 – 1000 mm²/s (cSt)
Operating Temperature	-25°C / +80°C
Distributor Flow Range	0.05 – 1.2 cm³ / stroke
Pump Motor Voltage	24 V DC / 220 V AC options
Oil Reservoir Capacity	3 – 8 liters
Suitable Oil Type	NLGI 000 – 2 (Grease or fine oils)
Number of Outputs (Distributor Block)	Ranges from 2 to 12

6. Distribution Unit: Structure and Working Principle

Distribution blocks are the most important part of the system. From here, the oil is transferred by dividing it into outlets. The pistons in the block move back and forth according to the pressure coming from the system, precisely determining the amount of oil. The amount output from each output can be adjusted and customized according to the need of the system.

Example: For a block with 6 outlets, each outlet can be adjusted to give 0.3 cm³ of oil.

7. Lubrication Points and Sample Flow Values

Lubrication Point	Oil Amount (cm³/stroke)	Explanation
Lineer Kızaklar	0.2	Low-speed sleds
Sprocket	0.8	High friction moving part
Bearing Block A	0.5	Medium speed bearings
Bearing Block B	0.3	Small diameter bearings
Gear System	0.7	Geared interlocking systems

8. Application Areas

Automatic lubrication systems are widely used in the following industries:

• CNC Machines
• Packaging machines
• Mobile construction equipment (excavators, cranes, etc.)
• Press and injection molding machines
• Paper and textile machinery
• Automation systems

9. Advantages

• Uninterrupted Lubrication: Oil reaches every point where it is needed regularly.
• Reduced Failure Rate: Parts life is increased by preventing wear.
• Energy Saving: Energy consumption decreases as parts work with less friction.
• Efficient Maintenance: Human intervention is minimized, maintenance intervals are extended.
• Traceability: In some systems, the lubrication cycle can be monitored via PLC.

10. Conclusion

Automatic lubrication systems allow machines to run longer with fewer failures. A properly designed and installed system significantly reduces maintenance costs and increases productivity. It is a great advantage for all businesses that want to contribute to industrial efficiency to evaluate this technology.