2010-05-10 ©SKF Slide 1 - FloSolve (Pty) Ltd Products... · 2016. 3. 31. · 2010-05-10 ©SKF...

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

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Market – segments

On road Construction Agriculture Special

Off-Highway

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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

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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

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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


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


Paper

Food &

BeverageMachine

toolHeavy

Industry


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.


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.


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


Food &

BeverageMachine

toolHeavy

Industry

Mining

Mineral processing

Cement

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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.


Food & Beverage

Machinetool

Heavy Industry


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 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 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 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


• 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


• Build-in real time clockenables monitoring of:

• service intervals

• running time

• fault time from … to ….

• failure analyses

Examples:

2010-05-10 ©SKF Slide 74


• Advanced system monitoring e.g. total grease delivery volume/lubrication cycle

• Considering the operation mode

Examples:

2010-05-10 ©SKF Slide 75


• 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


• 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 1 - FloSolve (Pty) Ltd Products... · 2016. 3. 31. · 2010-05-10 ©SKF...

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