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Project Overview:
In this project, we replaced an outdated lubrication system on a food sterilization machine with a more efficient, automatic lubrication system. The previous system utilized copper tubing, which is not ideal for high-pressure lubrication systems. Our updated design focused on simplicity, reliability, and ease of maintenance, while addressing key issues from the previous installation.
The new system pumps lubricant directly from a 120 lb. drum using a 60:1 air-operated grease pump. This pump, with a 3.15” bore and stroke, generates up to 6,000 psi at 100 psi air pressure. To ensure optimal performance, the pump is equipped with a low-level switch that monitors lubricant levels and a vent valve that controls pressure within the system.
At the heart of the operation is a 110VAC programmable controller, which automates the lubrication process. The controller manages the pump’s operation, ensuring consistent pressure is built within the distribution system, which is made up of ¾” tubing and manifolds equipped with injectors. Each injector is dedicated to a specific lubrication point and can be adjusted to deliver the precise amount of lubricant required.
Key components of the system include:
- 110VAC Programmable Controller with digital monitoring and fault notifications.
- Air solenoid and pressure switch to control air flow and monitor system pressure.
- Strobe light for fault notifications, such as low lubricant levels or system pressure issues.
- NEMA 4X Fiberglass enclosure with stainless steel hardware, protecting the system from environmental factors.
- 60:1 Air-operated drum pump, ensuring consistent lubricant delivery.
- 150 feet of ¾” OD tubing, connecting to a network of 28 injectors mounted on manifolds.
- Stainless braided hoses with Teflon lining, custom cut and crimped on site to connect each injector to the lubrication points.
Benefits of the Automatic Lubrication System:
- Reduced Downtime: Automated lubrication ensures that every critical point on the machine receives the proper amount of lubricant without manual intervention, reducing machine downtime and the risk of breakdowns.
- Extended Equipment Life: Consistent lubrication prevents wear and tear on moving parts, increasing the longevity of the sterilizer and reducing repair costs.
- Improved Safety and Maintenance Efficiency: The system’s design allows personnel to visually confirm lubrication at each point and manually grease if necessary, making it easier to maintain and service.
- Greater Reliability: With automated control and pressure management, the system ensures continuous, reliable lubrication even under high-pressure conditions.
By replacing the old system with this advanced lubrication setup, the machine now operates more smoothly and requires less manual maintenance, significantly improving overall efficiency.
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