The consistent and coordinated functioning of the entire pneumatic system is critical in achieving the desired functionality. Known as the “lifeline” of a system, air lubricators are of vital importance as every moving element must receive appropriate lubrication to decrease wear and friction. Yes! It helps prolong the life of tools and machines.
Therefore, whether it is air tools or high precision devices, knowing when and how to install and maintain the air lubricator should facilitate the design and functioning of the system in the best possible way. In this blog, we will cover what is air lubricators, types, when to install, how to install, and more. So, keep reading and make your pneumatic systems run smoother!
Figure no 1 Pneumatic lubricator
1) What is a pneumatic lubricator?
“Pneumatic lubricator can be defined as a device that is installed to serve the purpose of providing controlled lubricant to the moving parts of the compressed air systems and any attachments that require lubrication to operate efficiently.”
It allows pneumatic tools, cylinders and any other pneumatically actuated machine components to work normally. Since, it is important for them to get adequate lubrication. In its basic application, the lubricator completes a combination of units referred to as FRL (Filter, Regulator, Lubricator).
Figure no 2 FRL unit
The lubricator operates in a very efficient manner as it injects a fine mist of oil into the stream of compressed air. The mist is then carried by the airflow to the parts that require lubrication. Most lubricator pneumatics can be adjusted to suit the requirements of the system by adjusting the amount of oil dispensed.
Pneumatic systems are prone to high rates of wear, loss of efficiency, or even complete breakdowns without appropriate lubrication. By maintaining the internal parts properly lubricated, a pneumatic lubricator reduces wear in moving components, averts corrosion, and boosts the overall system reliability. This device finds use in manufacturing, automotive and construction industries where a lot of pneumatic tools and machines are in use.
Pneumatic system and components such as the modern anthropometric lubricators today have ergonomics designed with the user in mind and require less hands-on treatment. It is common for them to facilitate the checking of oil levels and it’s easy to immerse for rapid top-ups.
2) What are the types of pneumatic lubricators?
The pneumatic lubricators can be subdivided into the following classes: mist lubricator, micro-fog lubricator and proportional lubricator. Each one of them fulfills certain requirements made by the system.
i) Mist Lubricators: Mists lubricators generate atomic oil, carried in conjunction with compressed air. It is then delivered to nearby components such as valves and cylinders for smooth operation and lubrication. This is best for applications that require a higher oil supply and are effective over short distance.
ii) Micro-fog lubricants: Micro-fog-lubricators generate extremely fine oil mist particles. These particles are small enough to remain in suspension in the air. This will facilitate the travel of the lubricant longer distance in the pneumatic systems. Used in such systems where lubrication is required to be at a greater distance from the lubricator.
Figure no 4 Micro-fog lubrication
iii) Proportional Lubricators: Proportional lubricators, oil supply is proportional to the airflow in the system. They usually provide the same oil to air ratio for lubricant supply, irrespective of air pressure or the rate of air flow. This is therefore particularly advantageous in systems that have varied conditions of operations.
All types of lubricators lamented have provisions for controlling the rate of oil flow to suit any needed requirements of the system. The correct pneumatic lubricators increase operational dependability, prevent friction and wear, and secure the life of the pneumatic parts. You should regularly consider the maintenance measures for the lubricator so that you can achieve the expected performance at all times.
3) When do you install an air lubricator?
Air lubricator is necessary in systems that are likely to suffer from wear and tear due to excessive friction, environmental factors and time. Here are a few more instances where an air lubricator should be used:
! Continuous Use of System: Systems that run continuously or over extended periods tend to have moving parts wear out prematurely from abrasive contact. An air lubricator provides the optimum environment for effective functioning. It ensures that the parts are always provided with the right amount of lubricant thereby minimizing wear and tear.
! Heavy Load Operations: Pneumatic tools and equipment are widely used in industries such as manufacturing and construction. You know, heavy loads are placed on them. To prevent breakdowns and high maintenance costs, an air lubricator is used. It ensures that such heavy duty applications do not overstrain and smoothly operate.
Figure no 5 Heavy duty operations
! Variable Airflow Systems: In situations wherein airflow is variable, a lubricator ensures efficiency maintenance through even wear as a constant variation exists.
! Temperature Sensitive Operations: Excessive temperature in pneumatic systems can lead to accelerated expansion and degradation of components. An air lubricator helps dissipate heat resulting from friction and thermally induced damage to parts.
! Minimization of Downtime: Requires minimal maintenance or breakages for systems that may fail due to lack of lubrication. Systems tend to reduce wear and with high probability of lubricator failure. Moreover, unplanned downtime is cut down considerably, increasing normal operations.
! Increased Component Lifespan: When parts prone to wear such as seals and bearings are lubricated, the expensive equipment is able to last longer. Ultimately, it reduces the replacement costs.
! Defending against contaminate: In dusty, dirty, or moistened environments, air lubricators enhance the level of protection. This is done by applying a film of oil on the surfaces to prevent abrasives or corrosives from destroying components.
! Applications of Precision: When imprecise or jerky movements are not acceptable, it is the lubricator that comes in the field. You know, the lubrication between components will allow for smooth and accurate motions. Apart from this, it do not require a lot of force during operation.
Typically, the lubricator is mounted downstream of the air filter and regulator in an FRL, fitting the filter-regulator-lubricator configuration. For ideal performance, correct positioning and consistent checks are required. You are encouraged to pick the appropriate kind of lubricator for the system’s needs and set it properly so as to maximize lubrication effects. Well operated air lubricators improves not only the reliability of the system but also avoids costly system problems in future.
4) How to install an air lubricator in a pneumatic system?
You will not have any difficulties in installing an air lubricator in a pneumatic system. To avoid mistakes at installation and operation of the device, follow these series of steps:
Step 1) Choose the Right Lubricator: Lubricator capacity and the working pressure should be selected according to your system requirements and oil misting ability. Verify its compatibility with devices in your system.
Step 2) Turn off air supply: Close the air off for the pneumatic system and vent residual pressure. Yes! This guarantees safe conditions during the installation.
Step 3) Decide the Installation Location: Install the lubricator downstream of the air filter and regulator. Moreover, it should be close to the air pressure regulator in the filter, regulator, lubricator unit. In this configuration arrangement, air is first cleaned and regulated before any form of lubrication is done on it. Place it as close as possible to the equipment requiring lubrication for better lubricating effect.
Figure no 6 Lubricator installation
Step 4) Check Connections: Identify the inlet and outlet ports on the lubricator. These ports are generally labeled for easy identification of the airflow’s direction. Make sure the airflow of the system goes in the direction that is written on the lubricator.
Step 5) Attach the Lubricator: Use appropriate fittings to attach lubricator to the system. Use Teflon tape or any sealant material to prevent any leaks from occurring at the joints. Confirm that each and every connection is secure but do not apply excessive force because it may damage the threads.
Step 6) Fill the Lubricator: Take cap off the reservoir and put in a specific volume of oil as recommended for pneumatic oil system. Avoid overfilling, be careful to leave room for airflow.
Step 7) Adjust Settings: Activating air supply applies and turn the adjustment screw or knob to increase the flow rate of the lubricator.
Step 8) Test the Unit: Operate the system and monitor the performance of the equipment to see whether there is satisfactory application of lubrication to it. Examine the system for leaks or any abnormal occurrences and adjust it where necessary.
One more thing to notice here is that in order to maintain the effectiveness of the lubricator, some efforts should be made, such as cleaning the logs and refilling the reservoir.
5) Conclusion
The use of an air lubricator in a pneumatic system is of importance as it ensures that the equipment functions efficiently for an extended period of time and is also dependable. There are specific techniques for choosing and fitting an application which need to be considered seriously.
Lastly, one important thing to share with you is that FOYE’s F.R.L. Assemblies which are the G-Type Element Lubricators are suitable for varying requirements of pneumatic systems. These lubricators, together with filters and regulators, enable the system to function with clean and regulated as well as sufficiently lubricated air, enhancing its performance.