Showcase

For a manufacturer specializing in advanced CNC machining, we installed ReliaMAX™ Automatic Lubrication Systems on eight Okuma 560-V Vertical Machining Centers. These systems were designed to enhance equipment reliability, streamline maintenance, and provide precise lubrication delivery to critical components, including the X, Y, Z axes and the automatic tool changer (ATC) mechanisms.

Project Highlights

• Custom-Designed Systems: Each machine was equipped with a ReliaMAX™ Automatic Lubrication System featuring 2-kg pumps with low lubricant level monitoring, pressure gauge, and pressure relief valve to ensure optimal operation.
• Fault Monitoring Integration: Solid-state controllers with digital readouts were installed to monitor system performance, providing fault codes for easy troubleshooting. Multicolor LED indicators were mounted for immediate status updates, visible directly from the operator’s workstation.
• Enhanced Component Protection: High-pressure hoses replaced vulnerable OEM plastic lines, particularly for the ATC and Z-axis covers, reducing the risk of ruptures.
• Precise Lubrication Delivery: Progressive divider valves with proximity switches ensured accurate lubricant flow to all points, improving operational efficiency and extending the life of the equipment.

Power and Compatibility Considerations
To support the lubrication systems, we integrated 24VDC power supplies and ensured seamless compatibility with the existing electrical infrastructure. The system design allowed for easy integration into the machining centers’ pre-existing lubrication points, facilitating a smooth transition to automated maintenance.

Lubricant Selection and Initial Fill
The lubrication systems were filled with Lubrication Engineers’ Monolec® Extend EM Grease 1282, a polyurea-based grease known for its superior performance in high-temperature environments. This lubricant not only met the compatibility requirements with the original equipment manufacturer’s specifications but also provided exceptional protection against wear and corrosion. This lubricant also eliminated the separation and hardening exhibited by the OEM recommended lubricant.

Outcome
This project automated lubrication for critical components and provided the client with a more reliable and maintainable system. The enhancements reduced manual intervention, improved uptime, and mitigated the risk of premature wear and tear.

By tailoring the solution to the unique demands of CNC machining environments, the new system has set a benchmark for efficiency and reliability in the facility.