Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
NCIETM - 2017 Conference Proceedings

Concept of Automatic Lubrication System and

Comparison with Conventional Lubrication
System
Agam Kumar Malik1, Ankit Singh2, Mohit Hooda3
Graduate Student,
Department of Mechanical Engineering,
NCCE Israna,Panipat1,2,3

Abstract— Lubrication plays a major role in reducing in lubricate multiple points on a machine. These systems
friction between the piston and shear of moving mechanical dimensions vary from a simple single-port lubricator to
components to enhance the engine performance and complex dual-line, overturn units employing timers and
efficiency. This paper deals with the study and comparison alarms to deliver grease reliably to hundreds of grease
of Automatic Lubrication System with conventional
points. The design parameters of centralized grease
lubrication system. Automatic lubrication systems provide
a safer, more accurate form of machine lubrication. systems include the volume and frequency of grease
An automatic lubrication system (ALS), is defined as required at each point, the number of notch requiring
a centralized lubrication system, is a system that delivers grease, performing conditions, pump pressure, line
metered quantity of lubricant to multiple locations on a diameter and span to the grease points. When used and
engine while the engine is operating. The conventional preserved properly, centralized grease systems can help
lubrication system composed of manual lubricating to enhance technician productivity and simplify equipment
various parts of the engine. This system is usually time maintenance processes. The following is a complete
consuming. Previously we have to shut down system for
overview of centralized grease systems and the assistance
greasing. This study includes design and manufacturing of
automatic lubrication system, which allows to do greasing at
they offer, the various types, matter to watch out for and
frequent interval of time and in adequate amount. This tips on how to maintain them properly.
lubrication also ensures safety to machine components and
reduces labour. It ensures proper lubrication to each and II. AUTOMATIC LUBRICATION SYSTEM
every part of the engine. Centralized grease systems are designed principally to
make the work environment safer for maintenance
Index Terms- Automatic lubrication system, Oil systems, personnel by simplifying the process of accessing remote
Conventional lubrication system, Engine lubricant grease points, especially in restricted spaces, when
equipment is in operation. However, the primary use is
I. INTRODUCTION
derived from the continuous application of small amounts
The development of lubrication and its application in
of grease resulting in improved equipment life, due to the
machine and engine components in general, began in early
uniform supply of grease. Hand application is typically
70's of last century. From the view of improving
performed infrequently and may result in uneven amounts
lubrication in recent years more and more stress is given
of grease being applied, which can lead to over greasing
on the constant increase in materials and lubricants
resulting in damaged seals and elevated bearing
performance. The lubrication can be defined as a process
temperatures caused by grease churn
by which we introduce a layer of lubricant to reduce
Components
friction and reduces the wear between the two surfaces,
which are in relative motion to each other. This process A typical system consists of controller/timer, pump
includes the following activities: -the cleaning of w/reservoir, supply line, calculating valves, and feed
lubricants,- the checking the quantity of lubricants, - lines. All automatic lubrication systems share these main
refilling lubricants, Choosing the components:
with the correct lubrication system ensures firmness and 1. Controller/Timer –manages the pressure on the
allocates lubricants are best for a particular use. The system by turning pressure supply valves on and
abandonment machines will be avoided and the cost of off on the basis of either time or cycle. It can also
system maintenance will be drastically reduced. receive signals demonstrating restricted or failed
Automatic lubrication system (ALS), defined as a grease flow to the bearing.
centralized lubrication system, is a system that provides
metered amounts of lubricant to multiple locations on a 2. Reservoir – provides a total quantity of grease
machine while the machine is operating. Centralized that can be kept clean and readily available to the
grease lubrication systems are widely used in industrial system.
and heavy-duty mobile equipment applications to

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Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCIETM - 2017 Conference Proceedings

3. Pump – the flow of grease and builds up pressure A Single Line Parallel Lubrication Systems primarily
in the line(s). Pump size will vary banking on the consist of:
distance between the pump and the farthest - A Pump with either integral reservoir or with grease
injector. barrel mounting option
4. Metering Valves/Injectors– unit that take the - Air Maintenance Unit
lubricant to the application points. - Appropriate Injector devices
5. Feed lines - line that connects the metering - Electronic Control Unit (Timer)
valves or injectors to the application points. - Appropriate Tubing, Fittings, Valves and Gauges
Types
There are numerous different types of automatic During the operation cycle, the pre-set quantity of
lubrication systems including: lubricant is pumped to the various injector devices, which
 Single Line Parallel systems in turn deliver the pre-set quantities of the lubricant to the
connected lubrication points. The injector devices are
 Dual Line Parallel systems connected in parallel & operate independent of each
 Single Point Automatics other. The sequence of operation can be controlled by the
electronic control unit (Timer).
 Single Line Progressive systems
 Single Line Resistance Dual line parallel

The most commonly used Automatic Lubrication System

types are:
 Single Line Parallel,
 Dual Line Parallel and
 Single Line Progressive Multi port direct
lubricators
Single line progressive

Figure-3 Dual Line Parallel Automatic Lubrication System

A dual line parallel system is similar to the single line

parallel system in that it uses hydraulic pressure to cycle
adjustable valves to dispense measured shots of lubricant.
Figure 1- Single Line Progressive Automatic Lubrication System
It has 2 main supply lines which are alternatively used as
pressure / vent lines. The advantage of a two-line system is
In a single line parallel system, lubricant can be supplied that it can handle hundreds of lubrication points from a
either manually, with a grease gun, or with the help of a single pump station over several thousand feet using
fully automated system using electric or pneumatic pumps significantly smaller tubing or pipe. Operation begins
and progressive metering valves. More than a drilled when the controller/timer sends a signal to the pump to
manifold block, the SSV metering valve covers a series of start the lubrication cycle. The pump begins pumping
metering pistons, which accurately distributes lubricant lubricant to build up pressure in the first (the pressure)
from each outlet. Observable monitoring is provided with supply line while simultaneously venting the second
an indicator pin, which certifies a valve has completed a (vent) return line. Once the required pressure is reached, a
full cycle. predetermined amount of lubricant is dispensed by the
Single line parallel metering devices to half of the lubrication points via feed
lines. Once the pressure switch monitoring main supply
line pressure indicates a preset pressure in the line has
been reached, the system is hydraulically closed. The
controller shuts off the pump and signals a changeover
valve to redirect lubricant to the second main supply line.
The next time the controller activates the system, the
second main line now becomes the pressure line while the
first line becomes the vent line. The second line is
pressurized and the entire process is repeated lubricating
the remaining lube points.
Figure-2 Single Line Parallel Automatic Lubrication System

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Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCIETM - 2017 Conference Proceedings

Multi point direct lubricator IV. CONVENTIONAL LUBRICATION SYSTEM AND

COMPARISON WITH AUTOMATIC LUBRICATION SYSTEM
When the controller in the pump or external controller
Lubricate
activates the drive motor, a set of cams turns and activates
Reduces Friction by creating a thin film(Clearance)
individual injectors or pump elements to dispense a fixed
between moving parts (Bearings and journals).
amount of lubricant to each individual lubrication point.
Purpose of Lubrication System
Systems are easy to design, direct pump to lube point
•Seals The oil helps form a gastight seal between piston
without added accessories and easy to troubleshoot.
rings and cylinder walls (Reduces Blow-By) Internal oil
III. LITERATURE SURVEY leak (blow-by) will result in BLUE SMOKE at the tale
Review pipe.
There are many claims to the invention of the differential •Cleans As it circulates through the engine, the oil picks
gear but it is likely that it was known, at least in some up metal particles and carbon, and brings them back down
places, in ancient times. Some historical milestones of the to the pan.
differential include Two Chinese Buddhist monks and . •Cools Picks up heat when moving through the engine
engineers create South Pointing Chariots for Emperor and then drops into the cooler oil pan, giving up some of
Tenji of Japan. Documented Chinese reproductions of the this heat.
South Pointing Chariot by Yan Su and then Wu Deren, Absorbs shock When heavy loads are imposed on the
which described in detail the mechanical functions and bearings, the oil helps to cushion the load. •Absorbs
gear ratios of the device much more so than earlier Contaminants The additives in oil helps in absorbing the
.Chinese record Joseph Williamson used a differential contaminants that enter the lubrication system.
gear in a clock in the year1720. Rudolph Ackermann of
Germany inventeda four wheel steering system for
carriages, which some later writers mistakenly reported as
a differential in the year 1810. Modern automotive
differential patented by watchmaker On Siphore Pecqueur
in the period 1792-1852 of the Conservatoire des Arts Et
Mtiers in France for use on a steam carts Richard Roberts
of England patented gear of Compensation', a differential
for road locomotives in1832 Aveling and Porter of
Rochester, Kent list a crane locomotive in their catalogue
fitted with their patent differential gear on the rear axle in
the year 1874 First use of differential on an Australian
steam car by David Shearer was done in 1897. Packard
introduces the spiral gear differential, which cuts gear
noise in the year 1913. Packard introduced the hypoid
differential, which enable the propeller shaft and its hump
in the interior of the car to be lowered in1926. Vernon
Gleasman patented the Torsen dual drive differential, a
type of limited slip differential that relies solely on the
action of gearing instead of a combination of clutches and Figure-4 Conventional lubrication system
gears was introduced in the year 1958 The Engine lubrication system is considered to give a flow
Concept to the clean oil at the accurate temperature, with a
In project we have to develop the Automatic Lubrication appropriate pressure to each part of the engine. The oil is
System by using pneumatic cylinder and grease gun. It is sucked out into the pump from the sump, as a heart of the
less costly than the LINCOLN. It is less costlier than system, than forced between the oil filter and pressure is
automatic lubrication system based on hydraulics which fed to the main bearings and also to the oil pressure gauge.
was developed by LINCOLN The double acting The oil passes through the main bearings feed- holes into
pneumatic cylinder connected to handle of grease gun and the drilled passages which is in the crankshaft and on to
its other end is connected to compressor. When the bearings of the connecting rod. The bearings of the
compressor starts which deliver pressure at about 3 bar, it piston-pin and cylinder walls get lubricated oil which
moves the handle of grease gun to downward. And it dispersed by the rotating crankshaft. By the lower ring in
actuates the secondary piston of grease gun which delivers the piston the excess being scraped. Each camshaft
grease to required greasing point through nozzles bearing is fed by the main supply passage from a branch or
provided. When handle reaches to limit switch, it get tributary. And there is another branch which supplies the
actuated. Actuation of limit switch makes the pneumatic gears or timing chain on the drive of camshaft. The oil
cylinder operated oppositely. . Hence grease handle which is excesses then drains back to the sump, where the
occupies its original position. The whole process heat is being transferred to the surrounding air.
continues up to the time provided by digital timer.

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Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCIETM - 2017 Conference Proceedings

Comparison of manual and automatic greasing: There V. CONCLUSION

are certainly advantages to automatic application when From the Automatic Lubrication system it is concluded
compared to manual application. Theoretically, it is that the cost and man power require for the lubricating
preferable to apply small amounts of grease at short the various grease points can be eliminated. The loss of
intervals rather than large amounts of grease at long grease during greasing reduces as compared with the
intervals. With manual application, the trick is to apply as manual greasing. The system provides safety to the
much grease as possible without causing harm due to lubricating component and the operator. This system
over-greasing, thereby maximizing the re-lubrication enables the greasing to the points which are not reachable
interval. While this is fine for most grease-lubricated to operator and down time also reduces.
components, there are many applications that may benefit
from more frequent application or could be harmed by REFERENCES
large application volumes. There are lots of problems with [1] Gavaerts, R.: The World of Automatic Lubrication PERMA, 2009.
manual greasing such as 1) There is excessive loss of [2] Scarlett, N.A. (1967), “Use of Grease in Rolling Bearings,” Proc.
grease. 2) Equipment getting harmed due to over greasing. IMechE. Part 3A, 182, pp 167-171.
[3] H. Mikami: "Latest Trends in Lifespan Prediction for Lubrication
3) Excess time lost in lubrication. 4) Requiring variable
Grease and Grease," Hydraulics & Pneumatics (Japan).
labours [4] Ito, H., Koizumi, H., and M. Naka. (1995), “Grease Life Equations
Benefits for Sealed Ball Bearing.

Auto lube systems have many advantages over

conventional methods of manual lubrication:

1. All critical components are lubricated,

regardless of position or ease of access
2. Lubrication occurs while the machinery is in
operation causing the lubricant to be equally
distributed within the bearing and increasing the
machine’s availability.
3. Proper lubrication of critical components
ensures safe operation of the machinery.
4. Less wear on the components means extended
component life, fewer breakdowns, reduced
downtime, reduced replacement costs and
reduced maintenance costs
5. Measured lubrication amounts means no wasted
lubricant
6. Safety - no climbing around machinery or
inaccessible areas (gases, exhaust, confined
spaces, etc.)
7. Lower energy consumption due to less friction
8. Increased overall productivity resulting from
increase in machine availability and reduction in
downtime due to breakdowns or general
maintenance

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