Energy Efficiency: Lube

//Energy Efficiency: Lube
Energy Efficiency: Lube 2017-01-11T07:50:11+00:00

The more there is friction on the rolling element of bearing; motor exerts more power thereby increase your energy consumption. Suitable and correct amount of lubricants feed into the bearing will lessen friction, reduces load (HP), and make the whole drive system more efficient.

Bearing failure is a major cause of equipment downtime in today‘s industrial environment, most often resulting from improper lubrication. Improper lubrication scenarios include the contamination of the lubricant by dust, dirt and moisture, inadequate amounts of lubricant applied to the bearing, and/or over-lubrication of the bearing.

Each bearing failure directly impacts the production cycle. While bearings can be expensive, replacement cost alone is often miniscule compared to lost production and the cost to repair the damage.

Fig 1 shown that 51% of motor failure is caused by bearings. This is our experience in the repair of motors.

According to a recent study as shown in Fig. 2, 15% is caused by insufficient lubrication; 5% liquid contamination; 20% solid contamination (grease container exposed to environment not properly covered or sealed).

 

COMMON CAUSES FOR MOTOR FAILURES
FIG 2 CAUSES OF BEARING

Contamination is caused by foreign substances getting into bearing lubricants or cleaning solutions. These include dirt, abrasive grit, dust, steel chips from contaminated work areas and dirty hands or tools.

Why, in the age of technology, is this a problem? It is because many bearings are still lubricated manually. No matter how diligently a maintenance staff adheres to a lubrication schedule, it is a difficult task. Because employees are expected to manage multiple responsibilities in the lean environment of today‘s plants, it is common that proper lubrication is not considered a priority.

Solutions:

  • Use the appropriate type and correct amount of lubricant, avoid grease loss, and follow appropriate re-lubrication intervals.
  • Filter the lubricant using automatic lubricators and clean work areas, tools, fixtures and hands to reduce the risk of contamination.

Reference: http://www.slideshare.net/dmanney/why-electric-motors-fail
     http://vmpauto.com/article/v-debryakh-tribologii

Automatic Lubrication for Manufacturing Applications

ATS Electro-Lube manufactures self contained single-point and multi-point automatic lubrication products that provide effective, dependable lubrication for manufacturing equipment of all types. Our self-contained mechanical lubricators can deliver up to two full years of continuous lubrication, and can be installed almost anywhere—including remotely, as much as 30‘ from the lubrication point. Our devices are a safe, efficient alternative to daily manual lubrication.

We also offer a variety of accessories, including mounting brackets, control options and power options. ATS‘ motor-driven units, the ULTIMATE, TITAN, OILER and JACK series can all lubricate multiple points with a single unit via distribution blocks. Our TITAN, OILER and JACK units are refillable, for added convenience.

ATS‘ innovative auto lubers are ideal for bearing lubrication, engine lubrication, and any other machine lubrication needs your manufacturing processes may have. Our automatic mechanical lubricators deliver a reliable, consistent solution for any machinery that requires regular lubrication.

FIG 3 AUTOMATIC LUBRICATOR
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