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Customized
MDP Hydraulics
This product is an integrated intelligent centralized lubrication system specifically designed for medium and large-sized industrial rotating equipment (such as air compressors, fans, pumps, reducers, etc.). It integrates a high-performance lubrication station with the core intelligent control cabinet, achieving a complete closed loop from oil supply, filtration, cooling to automatic monitoring, protection and management. The system is based on the core design concepts of stability, reliability, efficiency and intelligence, aiming to provide continuous, clean, precisely controllable lubricating oil with temperature and pressure accuracy for the key friction surfaces of the equipment, thereby significantly extending the lifespan of the main equipment, reducing maintenance costs and ensuring production continuity.
• Appearance: It adopts an industrial-grade standard cabinet (as shown in Figure 1), with a white powder-coated finish, corrosion-resistant, and neat and tidy. The cabinet's protection level is usually IP54, which can effectively prevent dust and water, and is suitable for workshop environments.
• Control Core: Incorporates a high-performance programmable controller (PLC) or a dedicated control module, serving as the command center of the entire system.
• Human-machine interaction interface: Equipped with a high-definition color touch screen (HMI), it offers a fully Chinese-featured graphical operation interface. It can display all key parameters such as system pressure, temperature, liquid level, pump status, and running time in real time, and supports one-click parameter setting and mode switching.
• Interface and Wiring: The cabinet has a compact layout and standardized wiring (as shown by the dense interfaces at the top in the figure). It is equipped with a large number of input/output interfaces for connecting all sensors and actuators, and supports communication with the factory's DCS/MES system.
• Oil tank: Made of high-quality carbon steel or stainless steel by welding (as shown in Figure 2 in silver color), with a sturdy structure. It is equipped with a large maintenance opening, a liquid level gauge with visual scale, an air respirator, and an oil drain valve, facilitating maintenance.
• Power unit: It adopts a dual-pump redundant design (as shown in Figure 2, the two black motor pump groups at the top). One is in use while the other is on standby. In case of a main pump failure or insufficient system pressure, the standby pump will automatically switch without interruption, ensuring absolute continuous lubrication.
• Pipelines and Valves:
Red pipeline: Represents the high-pressure oil delivery pipeline, which conveys lubricating oil to the main equipment.
Blue/silver pipelines: Represent the return oil, cooling or control oil paths.
Key components are equipped with precision filters, pressure regulators, safety valves and pressure gauges/sensors to ensure the cleanliness of the oil and the stability of the system pressure.
Before the system was delivered, all the pipelines, wiring, and joint debugging between the control cabinet and the lubrication station body had been completed (as shown in Figure 2 in its entirety). The system was delivered on a sturdy wooden pallet. At the user's site, they only need to connect the main power supply, connect the lubrication points of the host, and connect the communication lines to quickly put it into use, which significantly reduces installation time and engineering costs.
• Dual-pump automatic switching: Automatically controls the start/stop and switching of the main/standby pumps based on pressure signals, and supports timed alternate operation to balance the lifespan.
• Automatic temperature regulation: Built-in/external electric heaters and coolers (optional) are equipped. They automatically start and stop according to the set oil temperature value, maintaining the oil temperature within the optimal working range.
• Real-time pressure monitoring: Multi-point pressure measurement, featuring multiple levels of protection such as low-pressure startup of backup pumps and emergency shutdown in case of extremely low pressure.
It has comprehensive fault monitoring functions including low oil level, high/low oil temperature, blocked oil filter, and abnormal pressure, and also has audible and visual alarm functions.
Output a standard "system operating normally" contact signal, which can be used for safety interlock with the main unit (such as the air compressor), ensuring that the main unit cannot start or immediately shut down safely when the lubrication system is abnormal.
The dual-pump redundant design completely eliminates the risk of machine shutdown caused by the failure of a single pump.
• Modular design: All major components are of brand products, making maintenance and replacement very convenient.
• Powerful self-diagnosis and data recording: The HMI screen can display the fault points in real time and record historical operation data and alarm information, facilitating preventive maintenance and rapid troubleshooting of faults.
• According to the actual operating conditions of the host, variable frequency control can be selected to achieve on-demand oil supply, resulting in significant energy savings (up to 20%-40%).
Project | Parameters/Description |
Applicable media | Mineral lubricants, synthetic lubricants, etc |
Nominal flow rate | 16 - 400 L/min (customizable) |
Rated pressure | 0.2 - 0.6 MPa (adjustable, customizable for higher pressure) |
Tank volume | 100 - 5000 L (customizable according to requirements) |
Control motor power | Standby pump motor: 1.5 - 22 kW |
Heater power | 3 - 18 kW (customized according to the volume of the fuel tank and the ambient temperature) |
Control power supply | AC 380V, 50Hz (or customized as per requirement) |
Control method | PLC fully automatic control, supports manual/automatic switching |
Human-machine interface | 7-inch color touch screen (or larger) |
Communication interface | Standardized RS485. Supports MODBUS RTU protocol (PROFIBUS, PROFINET, Ethernet, etc. are also optional) |
Protection class | Control cabinet: IP54; Motor: IP5 |
Environmental temperature | -10℃ to +45℃ |
The main lubrication system of large screw-type / centrifugal air compressors
Gearing lubrication for large-scale crushers, ball mills and rotary kilns in mining and cement industries
Lubrication of bearings for wind turbines, steam turbines and generators in the power industry
The lubrication systems for heavy equipment such as rolling mills and continuous casting machines in the metallurgical industry
• Customized Design: According to the actual operating conditions, space limitations and specific functional requirements of the customer's equipment, non-standard customization can be carried out.
• Whole machine testing: Before leaving the factory, conduct a combined operation test with a load for no less than 2 hours to ensure that the performance meets the standards.
• Professional support: Offer detailed installation instructions, debugging services and operation training.
• Quality Assurance: All core components are sourced from internationally/industrially renowned brands. The general warranty period for the entire machine is typically 12 months.
A1: The greatest advantage is "intelligent integration" and "high reliability". It integrates the lubrication station, oil pump, control cabinet, etc. before leaving the factory and completes the debugging. It is ready for use upon delivery, significantly saving the time for on-site installation and debugging. Its core intelligent control cabinet can achieve unmanned automatic operation, real-time monitoring, and multiple safety protections. Particularly crucial is the redundant design of two pumps in use and one as a backup, combined with the automatic switching function, ensuring the absolute continuity of lubrication and fundamentally protecting your expensive main equipment.
A2: Key interlocks are achieved through both hard wiring and communication methods. The control cabinet will output a dry contact signal (passive contact) indicating "lubrication system ready/operating normally" to the main controller of the air compressor. Only when the pressure, temperature, and level of the lubrication system are all normal will this contact close, allowing the air compressor to start. During operation, if extreme faults such as "low oil pressure" occur, this contact will immediately open, triggering the emergency shutdown of the air compressor, thereby preventing the main unit from being damaged due to lack of oil.
A3: The system usually has one pump designated as the main pump (which is always running), and the other as the backup pump. The operation logic is as follows:
1. Pressure drop switch: When the system pressure drops below the set limit, the control cabinet automatically starts the backup pump and both pumps operate in parallel until the pressure returns to normal, after which the backup pump stops.
2. Fault switch: If the main pump stops due to overload or other faults, the control cabinet will immediately detect the pressure drop and start the backup pump.
3. Timed rotation (optional function): A time period (such as every week) can be set, and the control cabinet will automatically switch the operating roles of the main and backup pumps to balance the wear on both pumps and extend the overall lifespan.
Intelligent features: Fully automatic operation (start-stop, switching, temperature control), centralized monitoring and parameter setting via touch screen, self-diagnosis of faults and historical record keeping, as well as remote communication capabilities.
Energy conservation is demonstrated as follows:
On-demand oil supply: An inverter can be optionally equipped. The oil pump's rotational speed and output flow can be automatically adjusted according to the actual load of the main unit, thus avoiding waste of electrical energy.
Precise temperature control: The intelligent system regulates the heaters and coolers (if any), maintaining the oil temperature within the optimal efficiency range and minimizing heat loss.
A5: The operation is simple and intuitive. It uses a fully Chinese graphical interface, similar to a smartphone. The main functions include:
• Monitoring home page: Displays all key data such as pressure, temperature, level, and pump status in real time.
• Parameter settings: Set target pressure, temperature, switching delay, etc.
• Manual mode: During debugging or maintenance, the pump, heater, etc. can be manually started and stopped.
• Alarm History: This feature allows you to view all recorded faults, including the time, type, and details, which is helpful for analysis.
A6: The system has a comprehensive self-diagnosis function. When a failure occurs:
1. The alarm light on the control cabinet will flash and the buzzer will sound (can be muted).
2. A prominent alarm window will pop up on the touch screen, displaying clear descriptions of the fault, such as "1# pump motor overload", "oil supply pressure sensor failure", "filter blockage", etc., directly pinpointing the source of the problem and significantly reducing the troubleshooting time.
A7: Absolutely. The control cabinet is equipped with industrial communication interfaces (such as RS485, supporting MODBUS RTU protocol). You can use it to upload all real-time data (pressure, temperature, status) and alarm signals of the lubrication system to the central control room. We can also customize communication modules that support other mainstream protocols (such as PROFINET, PROFIBUS-DP, Ethernet TCP/IP) according to your needs.
A8: The integrated lubrication station is an engineering product that has been designed and tested in an integrated manner. Its core advantages are as follows:
1. High reliability: The assembly, piping, wiring, and several hours of load testing under load are completed by professional personnel within the factory, eliminating the potential problems of incorrect connections and leaks that may arise from on-site assembly.
2. Clear responsibility: A single supplier is responsible for the performance, compatibility, and after-sales service of the entire system, eliminating the risk of shifting blame.
3. Cost savings: It saves a significant amount of labor and time costs for on-site design, assembly, and debugging, and has a better overall layout and appearance.
A9: You need to provide:
1. Host requirements: equipment model, total lubricating oil flow rate required, working pressure range.
2. Site conditions: installation space dimensions, environmental temperature, power supply conditions.
3. Functional requirements: control method, communication protocol, interlock signal type, special protection (such as explosion-proof, high protection level).
The production and in-plant testing cycle for standard configuration usually takes 3-4 weeks, and the customization with complex requirements will be accordingly extended.
• Daily maintenance: The main tasks include regular checks of oil levels, cleaning or replacing the air filters on the oil tank, replacing the filter elements of the double-tube filter based on pressure differential indications or operating time, and replacing the lubricating oil according to the lifespan of the oil. The control cabinet itself is basically maintenance-free.
• Warranty Policy: Generally, the entire machine (including the control cabinet) is covered by a 12-month quality warranty (starting from the completion of the debugging). Core components such as motors and gear pumps may have a longer warranty period. We provide detailed operation and maintenance manuals, on-site debugging (or guidance) as well as operation training services.
