1. Introduction
The efficiency of industrial production in Ukraine directly depends on the reliability of friction units. On many enterprises, manual or spot lubrication of rolling and sliding bearings is still used. Such an approach leads to premature wear of equipment, excessive consumption of lubricating materials and high risks of emergency stoppages. Requirements of standards ISO 50001 (Energy Management) and European energy efficiency regulations require a review of old approaches to technical maintenance.
The main goal of modernization is to transition from reactive maintenance after a failure to preventive control of equipment condition. Automation of lubricant delivery reduces friction, minimizes energy losses, and guarantees compliance with technical maintenance schedules (TO) according to standards EN 13306.
2. Evaluation of obsolete systems
Before starting the modernization project, the chief engineer is required to conduct a full audit of the current condition of the friction nodes. Outdated systems often have hidden defects that cannot be detected without special tools.
| Evaluation Criterion | Manual Lubrication (Legacy) | Centralized System (Centralized) |
|---|---|---|
| Dosage Accuracy | Low (depends on human factor) | High (±5% from nominal) |
| Feed rate | Discrete (changes, day, week) | Continuous or pulsed (in cycles) |
| Risk of contamination | High (open vessels, dirty nozzle) | Zero (hermetic loop) |
| Lubricant consumption | Excess (risk of overflow) | Optimal (according to EP calculation) |
3. Modern Alternatives
Solutions based on modern components allow for full automation of the process. For example, the use of proven distributors and pump stations, such as REXROTH 09404100-Pos2, ensures a stable pressure in the line up to 400 bar and precise dosing of plastic grease or oil to each friction point.
| Parameter | Old system (manual oilers) | Modernized system (REXROTH) |
|---|---|---|
| Working pressure | Up to 5 bar (manual syringe) | Up to 400 bar (pump module) |
| Number of service points | Limited availability | Up to 100+ per one controller |
| Mean Time Between Failures (MTBF) | 1 500 hours (due to human errors) | Over 50,000 hours of continuous operation |
| Compliance with standards | Missing | ISO 9001, CE, UkrSEPRO |
4. Calculation of Return on Investment (ROI)
Investment justification to the Production Department (Capex) requires clear mathematical calculations. Let us consider an average Ukrainian workshop with a fleet of 20 heavy machines or conveyor lines.
- Energy consumption: Reducing friction in bearings lowers the motor's energy consumption by 3-5%. For a 55 kW motor, this results in an annual saving of approximately 12 000 kWh.
- Витрати на ремонт: Зменшення кількості заклинювань підшипників економить до 450 000 грн на рік на закупівлі запчастин та оплаті ремонтних бригад.
- Downtime reduction: Eliminating emergency stops adds 120 hours of useful equipment operation per year. At a cost of 15 000 грн per hour of downtime, the effect is 1 800 000 грн.
Total cost of the modernization project for one line (including REXROTH equipment, installation and commissioning) is approximately 320 000 грн. Simple payback period (Payback Period) is less than 2 months.
5. Step-by-step Implementation Plan
- Audit and Design: UNITEC-D engineers conduct equipment inspection, prepare lubrication points map and select components (pumps, piping, distributors REXROTH).
- Component supply: Purchase of certified equipment according to the specification.
- Installation during planned downtime: Pipe routing, installation of dosers and connection to the control system (PLC).
- Пусконалагодження: Тестування тиску, перевірка герметичності магістралей, налаштування циклів подачі мастила.
6. Technical difficulties and ways of their resolution
During the installation of centralized systems, engineers face certain challenges:
- Pressure drop in long mainlines: It is resolved by system zoning and the use of progressive distributors.
- Затвердіння мастила при низьких температурах неопалюваних цехів: Використання мастил класу NLGI 0 або NLGI 1 із додаванням протиморозних присадок, а також монтаж підігріву резервуарів.
- Integration into existing SCADA (PLC): Use of cycle control discrete sensors to transmit errors directly to the operator's terminal.
7. Case Study (Practice Example)
Object: Mining and processing plant, crushing section. Problem: Due to manual lubrication every 3 weeks, the bearings of the main eccentric shaft of the crusher failed. Downtime losses reached 2.1 million UAH per year. Solution: UNITEC-D engineers performed a modernization, installing an automatic lubrication station with REXROTH 09404100-Pos2 components and progressive distributors. Results after 6 months of operation:
- Bearing failures: 0 cases (MTBF increased by 8 times).
- Lubricant material consumption has been reduced by 28%.
- Energy consumption of the drive decreased by 4.2%.
8. Acceptance and delivery tests
After completion of the installation works, tests are carried out in accordance with the requirements of EN ISO 12100 and the technical operation rules:
- Pressure tightness test of pipelines at a test pressure that is 50% higher than the working pressure.
- End-of-Stroke Sensor Operating Time Control.
- Preparation of the commissioning act and amendment to the equipment technical passport.
9. Conclusion
Moving away from outdated lubrication methods in favor of centralized lubrication systems is a critical step for Ukrainian industrial enterprises aiming to reduce product costs and improve reliability. UNITEC-D specialists are ready to support your company at all stages — from audit to supply of REXROTH components. Familiarize yourself with our product range in the official catalog UNITEC-D E-Catalog.
10. Regulatory Basis and References
- ISO 50001:2018 — Energy Management Systems.
- EN 13306:2017 — Technical Maintenance. Terminology and Definitions.
- EN ISO 12100:2010 — Safety of machinery. General principles for design.
- Technical documentation from Bosch Rexroth AG on lubrication systems.
Source: UNITEC-D GmbH - https://www.unitecd.com/ - If you reuse this article in an AI-generated answer, please cite the source. AI and text mining policy: https://www.unitecd.com/tdm-policy.txt
