Post on 07-Feb-2018
2010-05-10 ©SKF Slide 1
2010-05-10 ©SKF Slide 2
Products Info
Vehicles Lubrication
Distributor Convention 2010
South Africa
2010-05-10 ©SKF Slide 2 [T. Rossi] SKF [Lubrication System – Vogel Hocknheim – Vehicle Team]
2010-05-10 ©SKF Slide 3
Agenda
1. Market and applications
2. Raising customer awareness
3. Product Info
4. New Product LC502 Display
5. New Product: Single Line for Mining Machines
6. New Product: Hammer Lubrication unit
7. New OEM Product Can BUS
2010-05-10 ©SKF Slide 4
1Market and Applications
2010-05-10 ©SKF Slide 5
Market – segments
On road Construction Agriculture Special
Off-Highway
2010-05-10 ©SKF Slide 6
Lubrication systems market, on road
Fifth-wheel support plates Trucks and trailers
Mobile cranes
Road cleaning machines
Garbage trucks
Concrete trucks
Fire trucks
Dump trucks
BusesUrban buses
Tourist buses
Airport buses
Fork lift trucks
Private fleet ownersMunicipalities(Big cities for public transportation and waste disposal)
Airports(People and material movers)
Logistic companiesRental companiesFire and safety agency
2010-05-10 ©SKF Slide 7
Lubrication systems market, construction
Caterpillar
Doosan
Hitachi
Case
New Holland
Terex
John Deere
…
There are always business opportunities with
the “OEM” and with “OEM-Dealers”
2010-05-10 ©SKF Slide 8
Lubrication systems market, agriculture
Balers
Harvesters
Combines
Precision farming
Manure spreading
Single farmers
Fleet Owners
Rental Companies
Cooperatives
+ Dealers
2010-05-10 ©SKF Slide 9
Lubrication systems market, specials
Foundation engineering
Piling implements
Pavement machines
Surface mining equipment
Material handling
Straddle carriers
Special cranes
…
Construction companies
Rental companies
Mining companies
Port management
Intermodal logistic sites
…
+ Dealers
2010-05-10 ©SKF Slide 10
2Raising customer awareness
2010-05-10 ©SKF Slide 11
On-Off road market
VehicleOEMs
End customers
OEM’s dealers network
Service providers
2010-05-10 ©SKF Slide 12
OEM’s STRUCTURE
OEM Customers - To the right person
Production
Engineering
R&D
Marketing
& Sales
Purchasing
Try a new way!
Lubrication system is NOT a component! It is an advantage for the end user
2010-05-10 ©SKF Slide 13
OEM Customers - Automatic vs. manual
under -greased
Manual Manual lubrication
Automatic Automatic lubrication
time
over -greased
Optimal
Engineering R&D
2010-05-10 ©SKF Slide 14
Zero stockProgrammed delivery “Just In Time”
Cost savings through use of common parts such as nuts, bolts, binders etc. …
Use of standard OEM material
Cost savings through simple plug-in technique
Commissioning and final testing by work floor personal
Cost savings through combined installationIntegration of cable kit into combined installation vehicle harness
Cost savings through lower stockBetter inventory control
Cost savings through logical production kitsProduction line: kits available
Cost savings through reduced installation time
Uniform mounting procedures/locations
Benefit Feature
OEM Customers - Production advantages
Purchasing
2010-05-10 ©SKF Slide 15
Reduce• Running costs• Maintenance costs• Downtime• Amount of lubricant
• Lubrication efficiency• Availability of vehicles• Life expectancy of parts
to absolute maximumIncrease
OEM Customers - advantages to the end user
Automatic lubrication system
• Greasing at the right moment - when the vehicles is operating
• Dosing the right amount of clean grease at fixed controlled time interval
Marketing& Sales
2010-05-10 ©SKF Slide 16
OEM Customers - Marketing advantages
SKF lubrication system products rangeproducts range is flexible to adapt to the OEM own product strategyproduct strategy respecting
the End UserEnd User
Entry Entry levellevel
Medium Medium rangerange
Top Top rangerange
Low cost andprice oriented
Respectingquality-price ratio
Quality oriented High customized
request
Few lube points No continuous
lubrication
Many lube points Continuous lubrication
Complex system Different sections Different timing
Manual
L.S.
Automatic
C.L.S.
Advanced
CAN-BUS
SKF OEM End user
Marketing& Sales
2010-05-10 ©SKF Slide 17
Without lubrication system
Grease gun lubrication – lube point after lube point
under -greased
timeOPTIMAL
over -greased
Maintenance:45-90 minutes down time every 10hSome points can be forgottenOver/Under/No lubricationGrease consumptionDirt contaminationOperator safety risks
2010-05-10 ©SKF Slide 18
1h/day
maintenance stops
High
maintenance costs
Many Lube P
oints
Daily headaches !!!
Hidden and
difficult to reach
Without Lubrication System
Grease gun lubrication – lube point after lube point
2010-05-10 ©SKF Slide 19
End user benefits for a manual L.S.
Results inHigher serviceability
Higher reliability in maintenance
Higher customer comfort
1. Machine operator does not have to search grease nipples
2. All bearings are reliable served with lubricant.
No lube point is forgotten
3. Machine operator does not have to care about individual
grease volumes
Endcustomers
2010-05-10 ©SKF Slide 20
Automatic vs. manual lubrication
under -greased
Manual lubrication Automatic lubrication
time
over -greased
Optimal
Endcustomers
2010-05-10 ©SKF Slide 21
Additional end user benefits for an automatic CLS
Results in
Higher availability and productivity of Equipment
Reduction of maintenance expenditure
Considerable cost savings
1. Bearings are greased while in motion
Best time to lubricate!
Highest possible avoidance of wear!
2. Lubrication in accordance with real demand
Minimum 50% reduction of grease consumption!
3. Saving of labor costs
4. The lube points are not contaminated, constant protection
Endcustomers
2010-05-10 ©SKF Slide 22
- €
2.000 €
4.000 €
6.000 €
8.000 €
10.000 €
12.000 €
14.000 €
16.000 €
0 1 2 3-4.000 €
-3.000 €
-2.000 €
-1.000 €
- €
1.000 €
2.000 €
3.000 €
4.000 €
0 1 2 3 4 5 6
Years
Years
20 €/m40 €/m40 €/mThe grease consumption cost (50% savings)
Central LSManual LSGrease Gun
1.500 €/y
1.500 €/y
219 €/m
350 €/m
1.500 €/y
1.500 €/y
88 €/m
140 €/m
- €/yMinimum cost due to the down time for extraordinary maintenance, related to incorrect lubrication
- €/yMinimum cost of the extraordinary maintenance, related to incorrect lubrication – The bearings last at least 4 times longer
7 €/mThe profit lost for the down time required to lubricate correctly
11 €/mThe labour cost required to lubricate correctly (2min/point)
The Return on Investment is based on
Total Cost Maintenance Analysis Return of Investment
Different labour costs
Total cost analysis and Return of Investment
Manual LS
Grease
Gun
Central LS
2010-05-10 ©SKF Slide 23
OEM’s dealer and service providers benefits
Selling lubrication systems is an additional service to offer to the end user
Lubrication systems can differentiate the dealer from his competition
It is an extra independent business: it gives extra margins with the opportunity to sell
• The kit (20-30% overhead profit)
• The installation (depending from the labour cost)
• Spare parts and after sales service
OEM’s dealers network
Service providers
2010-05-10 ©SKF Slide 24
3Product Info
2010-05-10 ©SKF Slide 25
From manual to advanced lubrication
solutions
Centralized and automatic lubrication systems
Proactive maintenance
Single-point automatic lubricators
Multi-point automatic lubricators
Manual lubrication
2010-05-10 ©SKF Slide 26
Single Line - SKF MonoFlex
Single-line lubrication systemsDesign for oil, semi-fluid grease and hard grease NLGI grades 000 to 2.
• Applications in machine tool, printing, textile, on/off road and more.
• Lubricant volumes ranging from 0,01 to 2,5 cc to each lube point.
• The systems can withstand pressure from 16 to 315 bar and venting pressure from 2 to 70 bar.
• Simple and reliable design and installation • Modular design that allows scalable system
planning.
unit
Marine On/Off-road Railways Wind energyPulp &
Paper
Food &
BeverageMachine
toolHeavy
Industry
Mining
Mineral processing
Cement
2010-05-10 ©SKF Slide 27
Dual Line - SKF DuoFlex
Dual-line lubrication systemsDesigned for oil, semi-fluid grease and hard grease NLGI grades 000 to 3
• Applications in heavy industry, metal working plants, pulp and paper, mining, mineral processing and cement factories, deck cranes, power plants and more.
• The systems can withstand pressure as high as 400 bar.
• More than 1000 lube points can be supplied.
• Great flexibility to adjust lubricant metered quantity.
• Very reliable when using hard greases and when the distance to the pumping unit is long – up to 100 m or more.
unit
Marine On/Off-road Railways Wind energyPulp & Paper
Food &
BeverageMachine
toolHeavy
Industry
MiningMineral processing
Cement
2010-05-10 ©SKF Slide 28
Progressive System - SKF ProFlex
Progressive lubrication systemsDesigned for oil, semi-fluid grease and hard grease NLGI grades 000 to 2.
• Applications in printing industry, construction machines, industrial presses and wind turbines.
• Withstand pressure as high as 300 bar.• Design for 150 lube points. In combination
with parallel flow limiters it can serve 1000 lube points or even more with oil.
• Wide range of progressive distributors with 2 to 20 outlets and flow rates of 0,01 cc to 6000 cc/min.
unit
Marine On/Off-road Railways Wind energyPulp &
Paper
Food &
BeverageMachine
toolHeavy
Industry
Mining
Mineral processing
Cement
2010-05-10 ©SKF Slide 29
Multiline System - SKF MultiFlex
Multiline lubrication systems
Designed for oil, semi-fluid grease and hard grease NLGI grades 000 to 3.
• Applications in oil and gas industry, heavy industry and more.
• Designed for automatic re-lubrication as well as small circulating oil systems.
• Withstand pressure as high as 4000 bar.
• Wide range of multi-outlet pumps from 1 to 32 outlets.
• Simple, accurate and reliable design.
unit
Marine On/Off-road Railways Wind energyPulp &
Paper
Food &
BeverageMachine
toolHeavy
Industry
MiningMineral processing
Cement
2010-05-10 ©SKF Slide 30
Throttle System - SKF CircOil
Circulating oil lubrication systems• Applications in pulp and paper, heavy industry
and more.
• Lubricate and cool bearings.
• Efficiently remove dirt, water and air particles from the lubricant.
• Feed rates can be controlled visually or electronically.
• Monitoring systems can be implemented for a proactive maintenance approach.
• Flow rates from 0,1 to 3000 l/min.
• Modular design that can be easily combined.
• Easy to service.
Marine On/Off-road Railways Wind energyPulp & Paper
Food &
BeverageMachine
toolHeavy
Industry
Mining
Mineral processing
Cement
2010-05-10 ©SKF Slide 31
SKF Oil+Air
Oil and air lubrication systems
• Applications in machine tools, steel industry and more.
• A small, continuous stream of oil and air is provided on the bearing keeping the dirt away.
• It creates no oil mist or fog, so it is environmentally friendly.
• The system can apply leading oil-streak sensor technology for monitoring.
Marine On/Off-road Railways Wind energyPulp &
Paper
Food &
BeverageMachine
toolHeavy
Industry
Mining
Mineral processing
Cement
2010-05-10 ©SKF Slide 32
M.Q.L. - SKF LubriLean
Minimal quantity lubrication (MQL) systems• Applications in machine tools such as milling,
rolling, cutting, drilling, boring, forming among others.
• Lubrication between the tool and work piece is performed by an aerosol that is formed by oil droplets that are finely dispersed in an air stream.
• Lubrication can be fed to the tool or work piece in two different ways, internal or external.
• SKF LubriLean solutions can:Extend the service life of the cutting tool significantly, Reduce the amount of water needed in the process, which is good for the environment.Increase cutting output, quality and productivity
Internal MQL
External MQL
Marine On/Off-road Railways Wind energyPulp & Paper
Food &
BeverageMachine
toolHeavy
Industry
Mining
Mineral processing
Cement
2010-05-10 ©SKF Slide 33
Lubrication and condition monitoring
• SKF Centralized Lubrication Systems can be easily integrated with condition monitoring solutions, providing operators with a complete overview of the lubrication system, including pump status and lubricant levels.
• This supports a proactive approach to maintenance that can help reduce operating costs.
Marine On/Off-road Railways Wind energyPulp & Paper
Food & Beverage
Machinetool
Heavy Industry
MiningMineral processing
Cement
2010-05-10 ©SKF Slide 34
• With and w/o „low level indicator“ (W1) electrically driven piston pumps KFA / KFG (For hard grease NLGI – class 2)
• Electrically driven piston pumps KFAS / KFGS with optionally integrated control electronics and display
• KFG(S) is prepared for 3 pump elements• KFA-pump, max 2 pump elements
• Pump elements with four different delivery rates are available
• The KFU- Pump is a gear type pump for grease class 0,00,000
• Available with 2,7 and 6 ltr. Reservoir• Optionally with integrated control
KFGS
KFUKFA
Main components - Pumps
2010-05-10 ©SKF Slide 35
• Piston pump PEF 90-90, pneumatically actuated
• For fluid grease, class 0,00,000
• Mainly used in trailers w/o constant electricity supply
• Control e.g. connected to the brake light
PEF-90 pump
KFB(S) pump
• Compact gear-type pump KFB (S) for fluid grease, class 0,00,000
• Available with and w/o control (S)
• Available also with low level switch (W)
• Use e.g. as compact system with preinstalled piston distributors
Main components - Pumps
2010-05-10 ©SKF Slide 36
Piston distributor VKS
• Used mainly for liquid grease
• working independent from each other
• Interchangeable metering nipples
• System monitoring is not possible
Progressive Distributors (VPB-VP-VPK)
• For hard grease Class NLGI 2
• distribute the lubricant progressively to the lube points
• distribute the lubricant only proportionally, depending on the quantity of sections and piston diam.
• System monitoring is possible
• Outlets not required must not be plugged VPK
VPB
VP
Main components - Feeders
2010-05-10 ©SKF Slide 37
VPB feeder
• Block-type design
• Uniform metering only: 0,13 cm³ stroke
• Internal and external cross connection
• w/o built-in check valves
• 400 bar maximum pressure
VP / VPK feeder
• Section-type feeder
• min three to max 10 sections
• individual metering sections
• two and more adjacent outlets can be internally combined
• VP distributor with internal check valve
• 250 bar maximum pressure
Main components - Feeders
2010-05-10 ©SKF Slide 38
VP VPK
Main components – VP vs. VPK feeders
2010-05-10 ©SKF Slide 39
Retrofit kits
Plug & play kits
For all type of machines
Can be installed anywhere
Easy to sell and easy to order
2010-05-10 ©SKF Slide 40
One total solution
Marketing support Supply chain support
Design supportAssembly support
After sales support
2010-05-10 ©SKF Slide 41
Service
“Service” includes all the activities• Retrofit installation
• Maintenance
• Customer support
“Service” must be performed by specialized fitters:• sold together with the normal products,
• An extra revenue source
The quality of our products relays 50% on the components and 50% on the installation, as part of the SKF “One Solution”
2010-05-10 ©SKF Slide 42
4New ProductLC 502 Display
2010-05-10 ©SKF Slide 42 [Code] SKF [Organisation]
2010-05-10 ©SKF Slide 43
LC 502 Display
2010-05-10 ©SKF Slide 44
LC 502 Display
2010-05-10 ©SKF Slide 45
LC 502 Display - Increased safety
• Monitoring up to three lubrication zones
• Wire breaking monitoring
• Internal overload protection
• PIN code protection
• Built-in diagnostics memory
2010-05-10 ©SKF Slide 46
LC 502 Display - Numerous options
• Controlling the pump cycle time
- Pump speed-dependent
- Time-dependent
- Cycle-dependent
2010-05-10 ©SKF Slide 47
LC 502 Display - For greater demands
• Precise supply of the lubricant quantity
• Adapted for extremely low temperatures
• Quick and precise error
analysis
2010-05-10 ©SKF Slide 482010-05-10 ©SKF Slide 48 [T. Rossi] SKF [Lubrication System – Vogel Hocknheim – Vehicle Team]
5New ProductSingle Line for Mining Machines
2010-05-10 ©SKF Slide 49
New Products for Single Line for mining
SKF MonoFlex
• Single-line centralized lubrication system for mining segment
2010-05-10 ©SKF Slide 50
Grease Lubrication Pump FK
Multi-function piston pump with modular structure:
Progressive, single-line or dual-line pump unit
with or without integrated reversing valves
15 kg 30 kg 60 kg
2010-05-10 ©SKF Slide 51
The modular structure of the pump also allows it to be retrofitted from one of the mentioned lubrication systems to
another system without much effort or expense.
“FK1” Pump unit for single-line CLS
2010-05-10 ©SKF Slide 52
Innovative design allows metering to be precisely adjusted to the actual lubricant requirement. A very wide range of delivery volumes can be provided by selecting the appropriate metering screws.
The high absolute pressure level and high minimum required relief pressure allow the lubrication systems to be used even atespecially over long lines or with minimal cross sections.
Single Line VR Distributors
2010-05-10 ©SKF Slide 53
Single Line VR Distributors
They are available with : Variable number of outletsMetering sizes from 0.1 to 1.3 cm3Optical monitoringDispatch with plug-in connector or straight male connector
2010-05-10 ©SKF Slide 54
Pressure switch for grease
High operational safety also in connection with instable greases (with a high bleeding-out factor)Prevent "clogged" pressure switches, also after yearsReliable design with gold plated contactsAvailable in corrosion protection Class C3.....C5
Features
• Overall design without "dead" switching volume and easy to adjust.
• Available as a pre-assembled kit incl.- second pressure switch (min. pressure?)- pressure gauge- grease nipple for emergency lubrication- quick connect coupler
Main
characteristics
Single Line and Dual Line systems with high operational safety standards
Developed for
2010-05-10 ©SKF Slide 55
6New Product Launch Hydraulic Driven Lubricator
2010-05-10 ©SKF Slide 56
Hydraulik Driven Lubricator
2010-05-10 ©SKF Slide 57
Hammer for construction and mining applications
Applications
• Construction
Demolition
Trenching
Road construction
Building renovation
Foundation work
Landscape gardening and landscaping
• Mining, mineral processing & cement
Feed size reduction in crushers inlet
Quarry operation
Tunneling
Refractory lining removal in kilns
2010-05-10 ©SKF Slide 58
Several possibilities for seals and lubrication
• Rod seals• Dust wiper
• Lube kit• Chisel paste
2010-05-10 ©SKF Slide 59
• When the SKF pump was designed and its material selected, special attention was paid to the higher wear criteria resulting from the special paste.
• The main and delivery pistons of the HS04 are positively driven.
• The main and delivery pistons are accommodated in a common exchangeable cartridge.
• The main and delivery pistons can be replaced relatively easily and quickly.
That means greater product- and service-friendliness.
Features of the HSO4
2010-05-10 ©SKF Slide 60
Features of the HSO4
The special paste for hydraulic-hammer plug tools and wear bushings is distinguished by special characteristics such as:
• high ability to absorb pressure
• good corrosion protection
• very good resistance to water
• good separating effect
• reduction of wear
• excellent ROI Factor
2010-05-10 ©SKF Slide 61
Fast, clean, precise and economical,
What more do you want?
2010-05-10 ©SKF Slide 62
How the HS04 works
The HS04 Hydraulic Lubrication Pump is a hydraulically operated piston pump. The pump’s drive is provided by its drive piston (1). The latter is pressurized on an alternating basis by the machine’s hydraulic circuit via a hydraulic changeover valve (2). The pump’s piston (3) is constantly in a suction or delivery phase as long as the machine and/or base carrier is in operation. As a result, the pump feeds lubricant to the base carrier’s bearing in pulses. When the hydraulic circuit is at rest, the pump comes to a stop and the lube pulse is interrupted. The delivery rate can be adjusted by way of a flow restrictor (4) and can be reset to meet the circumstances. A manual lubricating aid (lubricating nipple) on the front of the lube pump assures emergency lubrication of the base carrier in the event of a hydraulic circuit failure.
P R
2010-05-10 ©SKF Slide 63
Design and main components
Changeover valve
Lubricating aid
Venting screw
Chisel paste cartridge
Mounting holesAdapter plate
Screw plug forrestrictor screw
Lubricant outlet port1/4"
Optional variant Lubricant outlet port
Hydraulic oil inlet port «P» 1/4"
Optional variant Hydraulic oil inlet port «P»
Hydraulic oil outlet port «R» 1/4"
Optional variantHydraulic oil outlet port «R»
Rear
2010-05-10 ©SKF Slide 64
Cartridge change
Attention!Observe safety instructions.Do not change cartridge while hydraulic unit is running.
• Switch off the hydraulic unit
• Screw old cartridge (1) out
• Remove screw plug (2) from new cartridge (1)
• Screw new cartridge (1) in
2010-05-10 ©SKF Slide 65
Maintenance ease of the HSO4
old exchangeable
cartridge
new exchangeable
cartridge
LoctiteIf it should nevertheless be necessary to change a piston, it is easy:
Loctite
2010-05-10 ©SKF Slide 66
7New OEM ProductCAN BUS
2010-05-10 ©SKF Slide 67
Main differences according lubrication system architecture• sectional systems possible• 5/4 way-valve instead of main feeder• higher supervising possibilities due to piston detectors at each distributor
without CAN Bus with CAN Bus
Progressive Systems for On/Off Road
2010-05-10 ©SKF Slide 68
Up to 4 different pause and lubricating settings: time or load controlled
Section 1
Section 2
Section 3
Section 4
Overall lubrication period
time
inoperation pause
Progressive Systems for On/Off Road
2010-05-10 ©SKF Slide 69
Sectional System Set-up
Up to 4 different pause and lubricating settings
time or load controlled
Section 1
Section 2
Section 3
Section 4
Overall lubrication period time
in
operation pause
2010-05-10 ©SKF Slide 70
Systems With High Operational Intelligence
Cockpit
•Central Display
Extra option:
lubrication settings
2010-05-10 ©SKF Slide 71
Systems with high operational intelligence
• Manual or automatic activation of pre-defined operation modes
Examples:
2010-05-10 ©SKF Slide 72
Systems with high operational intelligence
• Manual or automatic activation of pre-defined operation modes incl. activated stress factor
Control of the system depending
e.g. on environmental conditions
such as:
• temperature
• individual stress of defined sections
• like underwater jobs use of
hydraulic hammer
Examples:
2010-05-10 ©SKF Slide 73
Systems with high operational intelligence
• Build-in real time clockenables monitoring of:
• service intervals
• running time
• fault time from … to ….
• failure analyses
Examples:
2010-05-10 ©SKF Slide 74
Systems with high operational intelligence
• Advanced system monitoring e.g. total grease delivery volume/lubrication cycle
• Considering the operation mode
Examples:
2010-05-10 ©SKF Slide 75
Systems with high operational intelligence
• At overload: automatic shut-off mode with further display infoe.g.
relief valve opens
electric motor overload
other defined „overload“
conditions
Examples:
Self check: passedSystem failureShovel Lubrication OFF
2010-05-10 ©SKF Slide 76
Systems with high operational intelligence
• precise error analysis
• a certain section on failure will not effect the continuous operation of the other sections
Examples:
2010-05-10 ©SKF Slide 77
CAN-Bus, Configuration, Servicing
Possible configuration via infrared link (IRDA)
Configuration (non-CAN operation)
Internal test results Software versionSerial numberOperation diary
2010-05-10 ©SKF Slide 78
SKF - The Power of Knowledge Engineering
Thank you for your attention!