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Customized
MDP Hydraulics
The Industrial Centralized Lubrication Station is an indispensable core subsystem in modern high-precision, high-load, and continuous production systems. It fundamentally revolutionizes the traditional decentralized, intermittent, and labor-dependent lubrication mode by establishing a closed-loop controlled lubricant supply and management network, enabling precise lubrication at regular intervals, in fixed quantities, with defined quality, and at specific locations for individual large equipment or groups of multiple equipment with dozens or even hundreds of friction points.
This system is not merely a simple "fuel supply device", but rather a comprehensive equipment health guarantee center that integrates fluid power, precise filtration, intelligent control, and real-time diagnosis. Its core mission is to create an almost ideal lubrication environment, minimizing the friction and wear of critical moving components (such as bearings, gears, guides, and screws), thereby maximizing equipment availability, operational accuracy, and service life, while significantly reducing unplanned downtime, energy consumption increase, and maintenance costs caused by improper lubrication.
The lubricating oil is stored in stainless steel or carbon steel oil tanks equipped with air respirators (to prevent contaminants from entering).
Built-in or bypass type heaters/coolers (depending on the environmental configuration) maintain the oil temperature at the optimal viscosity range (typically 40 ± 5°C).
The liquid level sensor (magnetic flap/float type) continuously monitors the oil quantity and issues an early warning when the level is low.
The twin gear pump set (one in use and one as backup) draws oil from the oil tank. In the event of a failure of the main pump, the backup pump automatically switches without interruption through the pressure switch monitoring, ensuring zero operational disruption.
The oil first passes through a coarse filter (100-150 μm) for filtration, protecting the pump body.
Then it enters the high-pressure pipeline and passes through the double-tube high-pressure filter at the core. This filter uses high-precision filter elements with βₓ(c) ≥ 200 (optional 10μm, 5μm, 3μm), which can capture extremely fine wear particles. The unique bidirectional switching valve design allows for the replacement of clogged filter elements without stopping the system, and the differential pressure sensor will promptly indicate the filter element clogging status.
Clean high-pressure oil is delivered to the distribution unit at the lubrication points. The system can be adjusted according to the requirements:
Progressive distributor: The oil flows sequentially through the pistons in a fixed order, delivering equal or proportional amounts of oil to each point. If a certain point becomes blocked, the entire sequence will stop, and it has a fault indication function.
Volume-type distributor: Each outlet discharges a fixed volume of oil fluid in each cycle. Each outlet operates independently and does not affect each other.
Oil-gas mixture system (optional): Mix a small amount of oil with compressed air to create fine oil mist, which is used for long-distance and high-efficiency lubrication. This is particularly suitable for high-speed spindles and a large number of light-load bearings.
The distributor precisely delivers the oil to each lubrication point through a pipeline (usually made of stainless steel or nylon armored tubing).
Key system parameters (main line pressure, filter pressure difference, oil tank temperature, oil level, pump operating status) are collected in real time by sensors.
The intelligent lubrication controller (PLC or dedicated control unit) processes these signals, executes the preset lubrication procedures (which can be based on time intervals, equipment operation cycles, or external triggering signals), and triggers graded alarms (early warning, minor fault, major fault) in case of any parameter abnormalities. In case of a major fault, it can output a shutdown signal to interlock the main equipment.
• Power Unit:
Pump: Utilizes internal and external gear pumps or cycloidal rotor pumps to provide a low pulsation and highly stable flow output. The bearings are of long-lasting wear-resistant type, and the shaft seal employs a double lip-mouth type oil seal to ensure zero leakage. The volumetric efficiency is ≥ 92%.
Motor: Fully enclosed air-cooled (TEFC) three-phase asynchronous motor, with insulation class F and protection class IP55/IP65. It is suitable for humid and dusty environments. Standard equipped with thermal overload protection.
• Filtration and Purification Unit:
Double-barrel filter: The barrel body is made of carbon steel or stainless steel, with a maximum working pressure of up to 4.0 MPa. The filter element is composed of multiple layers of glass fiber composite material, which has a large pollutant-capturing capacity and a gradual increase in pressure difference. The switching valve adopts a lifting rod design, ensuring a smooth and impact-free switching process and avoiding fluctuations in system pressure.
• Control and Diagnosis Unit:
Controller: Based on industrial-grade PLC, it is equipped with a color HMI touch screen. The programming software is user-friendly and allows for graphical settings of lubrication cycles, oiling times, monitoring parameters and alarm thresholds.
Communication and Integration: Standardized with Modbus TCP/IP, PROFINET, EtherNet/IP and other industrial Ethernet interfaces, as well as 4-20mA analog input/output. It can be seamlessly integrated into the factory's DCS/MES system to achieve remote monitoring and data collection.
Diagnostic function: Built-in black box feature, which records all alarm events and historical trends of key operating parameters, facilitating fault tracing and analysis.
• Structural Design and Adaptability:
Overall base: Made by welding heavy-duty channel steel and undergoes stress-relieving annealing treatment to ensure long-term stability. The surface is sandblasted for rust removal and then coated with epoxy resin anti-corrosion paint.
Mobility: Equipped with 4 heavy-duty polyurethane swivel casters (2 of which have brakes), and a forklift slot is provided for easy positioning and movement.
Selecting the appropriate lubrication station requires a systematic calculation. The following are the key selection steps:
Step | Parameter | Calculation/Selection Method | Example/Explanation |
1. Demand assessment | Number of lubrication points (N) | Count all the points that require lubrication, such as bearings, gears, guides, etc. | A rolling mill may have 120 lubrication points. |
Single-point fuel consumption (Qp) | found in the equipment manual or calculated based on the bearing inner diameter, rotational speed, and operating conditions (using common chart methods) | For a φ100mm bearing operating at medium speed, it might require 0.3 mL/h. | |
Lubrication cycle (T) | determined based on the equipment's load, speed and working environment. | In heavy-load and high-temperature environments, it may need to be performed once every 15 minutes, while for light loads, it can be done once every 8 hours. | |
2. System Calculation | total oil consumption (Qtotal) | calculated as Qtotal = Σ (Qp of all points) | With 120 points and an average of 0.2 mL/h, then Qtotal = 24 mL/h. |
Pump station discharge selection: | Theoretical discharge of the pump ≥ (Qtotal / safety factor K) / efficiency | K is usually set between 1.2 and 1.5. Need ≥ 24. 1.3 / 0.92 ≈ 34 mL/min. Select a pump with a discharge of 40 mL/r. | |
Tank capacity (Vtank) | Vtank ≥ (total filling volume of the system + circulation volume) * 1.5 | The lowest oil level must submerge the oil suction port. Usually, it is 3-10 times the pump's per-minute discharge volume. It is recommended to be ≥ 100L to ensure heat dissipation and sedimentation. | |
3. Component Selection | Pump Type | The type of pump (progressive or volumetric) is selected based on the layout of lubrication points, the variability of oil quantity requirements, and the diagnostic requirements for faults. | The oil quantity required at different points is different; therefore, a volumetric pump is chosen. If strict sequential monitoring is required, a progressive pump is selected. |
Filter accuracy: | It is selected based on the most precise friction pair gap of the equipment. Generally, it is 1/3 of the required accuracy of the main unit. | High-precision spindle bearings need 3 μm, while ordinary bearings and gears can be 10-25 μm. | |
Control system | Choose according to the requirements of automation level: basic timing type, programmable logic type, intelligent type with network communication. | If connected to the factory Internet of Things, the intelligent controller with industrial Ethernet must be selected. |
Category | Item | Specifications and Options |
Basic Parameters | Model Series | LCS-50, LCS-100, LCS-200, LCS-500 (The numbers represent the fuel tank volume, in liters) |
Rated pressure | 2.5 MPa / 4.0 MPa / 6.3 MPa (optional) | |
Rated flow rate | 6 - 5000 mL/min (depending on pump configuration) | |
Applicable media | Mineral lubricating oil, synthetic lubricating oil, grease (requires special pump) ISO VG 15 - 680 | |
Power unit | Motor | Three-phase - 380V/50Hz or 440V/60Hz, 0.37 - 7.5 kW, Protection class IP55, Insulation class F |
Oil pump | Gear pump/rotor pump, cast iron or stainless steel housing, lifetime lubricated bearings | |
Filter unit | Filter | Dual-tube switchable type, with filtration accuracy of 3, 5, 10, 25 μm (optional), equipped with differential pressure sensor |
Filter element material | Glass fiber / Stainless steel sintered mesh | |
Control unit | Controller | Programmable PLC + 5.7"/7" color HMI, multi-language interface |
Input/Output | 8DI / 6DO (standard), expandable, supports analog input (pressure, temperature) | |
Communication interface | RS485, Ethernet (Modbus TCP), optional PROFIBUS/Profinet | |
Protection functions | Overload protection of the motor, phase sequence protection, low liquid level, high oil temperature, filter blockage, abnormal pressure, etc. | |
Structure and Environment | Tank Material | Carbon steel (with internal anti-corrosion treatment) / 304 stainless steel |
Pipeline material | High-pressure stainless steel hose/hard pipe, socket-type connectors | |
Working temperature | -10°C to +60°C (Heaters are required in low-temperature environments) | |
Protection level | Control box IP65, Entire machine IP54 (can be increased as needed) | |
Noise level | < 70 dB(A) at a distance of 1 meter |
Place the oil station in a level, stable, well-ventilated area that is convenient for operation and maintenance.
Very important: Make sure the oil suction pipe is short and straight, fully submerged below the oil surface to prevent air from being sucked in.
The lubrication pipeline connected to the main unit should be fitted with a dedicated adapter or flange to ensure a reliable seal. It should also be flushed and pressure tested.
Initial oil filling: Fill the designated grade of new oil into the oil level gauge to the upper limit using an oil filling vehicle equipped with a filter.
Manual venting: Activate the motor, check the rotation direction of the pump (with arrow markings), and perform venting operations at each distribution outlet and the system's high point until a continuous oil flow without bubbles is observed.
Parameter settings: Set the lubrication cycle, the time for each oil injection, and the various alarm thresholds on the HMI.
Trial operation: Run the system at no-load for 2 to 4 hours to check that all joints are leak-free and that the pressure and temperature remain stable.
Daily: Visual inspection of oil level, for any leaks, and pressure gauge readings.
Monthly: Check the pressure difference indicator of the filter. If necessary, switch and replace the filter element. Clean the oil tank breather.
Every half year/annum: Decide whether to change the oil based on the oil analysis report. Take samples for testing, and analyze the viscosity, moisture, acid value and contamination level.
Every two years: Based on the operating conditions, inspect the wear of the pump and replace the lubricating grease for the motor bearings.
Wind turbine gearbox lubrication, mining crushers, port cranes, steel continuous casting machines, injection molding machines, paper machinery, ship deck machinery, large gear transmission devices.
For a hot rolling production line of a steel enterprise, after installing our centralized lubrication system, the failure interval of the rolling mill bearings increased from an average of 6 months to over 24 months. The annual savings from bearing replacements and downtime losses exceeded 1.2 million RMB. The system investment payback period was less than 8 months. The oil consumption decreased by 65%, and the cost of waste oil treatment also dropped simultaneously.
a full life-cycle service including on-site investigation, scheme design, non-standard customization, installation guidance, commissioning training and lifelong after-sales support. Our engineering team will work closely with you to ensure that the lubrication system is seamlessly integrated into your production process and becomes a solid foundation for the reliability of the equipment.
Answer: The core advantages lie in precision, reliability, efficiency and economy. Traditional manual lubrication often leads to uneven lubrication (either too much or too little), reliance on human intervention, and potential omissions. Our system can achieve fully automatic, quantitative and timed precise lubrication, ensuring that each friction point receives the just-right amount of oil, avoiding waste and wear. It can significantly reduce equipment failure rates, extend equipment lifespan, and save over 50% of lubricant consumption and a large amount of labor costs.
A: For critical production line equipment that cannot tolerate unexpected shutdowns (such as continuous casting machines, power generation units, and large-scale production lines), the redundant configuration of one pump in use and one as a backup is strongly recommended and even necessary. When the main pump fails, the backup pump can automatically and seamlessly start up, ensuring continuous lubrication and allowing time for planned maintenance. For non-consecutive operations or auxiliary equipment, an economical single-pump configuration can be chosen.
A: This requires professional calculation based on parameters such as the total number of lubrication points on the equipment, the single-time oil consumption per point, and the lubrication cycle. You only need to provide the equipment model or relevant parameters, and our application engineers can calculate and select for you for free. The simple estimation principle is: the oil tank capacity should be sufficient to allow the system to operate for a certain period of time at the maximum oil consumption rate, and also take into account the requirements for heat dissipation and impurity sedimentation.
A: The filtration accuracy depends on the gap requirement of the most precise friction pair in your equipment (such as high-precision main shaft bearings). The general principle is that the filtration accuracy should be less than the minimum oil film thickness. 10μm is a common standard for general industrial equipment. For high-speed spindles, hydraulic systems, etc., high-precision filter elements of 3μm or 5μm can be selected. We will provide you with professional advice during the scheme design.
A: Absolutely. Our intelligent lubrication station is equipped with industrial Ethernet (such as Modbus TCP/IP, PROFINET) and standard I/O signal interfaces. You can remotely monitor the operation status and fault alarms of the oil station, receive lubrication data, and easily integrate with the factory's DCS/MES system to meet the intelligent management requirements of Industry 4.0.
A: The installation is straightforward. Our gas stations are designed in an integrated and modular manner, and have been tested and debugged before leaving the factory. You just need to place it near the equipment, connect the power supply, and lay out the lubrication pipeline kits (usually flexible hoses) that we provide and connect them to the various lubrication points on the equipment. Our technical team can offer detailed installation guidance or on-site support services.
A: The maintenance work is very simple. It mainly involves regular inspections, and the workload is extremely small.
• Daily: Observe the liquid level and pressure gauge.
• Regularly: When the filter differential pressure alarm occurs, switch and replace the filter element (the process only takes a few minutes and does not require a shutdown).
• Long-term: The lubricating oil should be replaced based on the oil test report (usually once a year). The efficient filtration of the system can significantly extend the lifespan of the oil.
A: Our system has a comprehensive self-diagnosis and indication function.
• The controller HMI touch screen will clearly display the specific faults (such as "Pump 1 overload", "Filter clogged", "Low liquid level").
• Hardware indication: The distributor has an indicator rod to show whether it is working, and the filter has a differential pressure sensor.
We offer a detailed fault code manual and 24-hour technical support, which enables remote guidance to quickly resolve common issues.
A: Yes. We have a dedicated centralized grease system. Due to the high viscosity and poor流动性 of grease， this system will use a special high-pressure plunger pump and a grease distributor suitable for grease. If you need a grease system， please specify the type of medium when making the inquiry.
A: Customization services are one of our core advantages. We can offer completely customized solutions based on your equipment layout, the location and quantity of lubrication points, special oils, extreme temperature environments, and explosion-proof requirements. This includes personalized designs for the shape and size of the oil tank, pump group configuration, control system functions, and installation methods, ensuring that the system perfectly matches your equipment.
