Lube Corporation was founded in 1964 primarily by developing and manufacturing centralized lubrication systems of industrial machinery manufacturers. For more than a half a century, we have been developing centralized lubrication equipment and lubricants which are best suited to satisfy the needs of various types of industrial machinery. We have been working closely with and listening to a wide range of industrial machinery manufacturers and users globally in hopes our future products not only meet but exceed their expectations. Together with our Global LUBE Team, we are committed to serving our customers as well as the manufacturing industry with the highest quality products and our exceptional customer service for the next 50 years and beyond. Our globalization which has been accelerating rapidly over recent years, will allow us to achieve this goal while caring for the future of our global environment. October 2016 Eijiro Horikoshi Chief Executive Officer Purpose of the LHL system Our corporate mission is to solve the problems that have remained outstanding on the boundary between machine manufacturers and machine users over many years. The problems in their respective specialized areas which we are referring to here are automation and machinery maintenance at manufacturing sites, as well as the protection of the global environment. We aim to integrate these problems and solve them by introducing the LHL system, and support our customers to achieve the desired levels of productivity, maintainability and environmental consciousness. We have been developing the LHL system in cooperation with machine users and machine manufacturers by listening to their opinions, worries and concerns about saving limited resources all over the world. Features and target of the LHL system Our high-quality and highly reliable LHL lubricant has very high film thickness retention, load-carrying capacity and interfacing properties. It is able to spread over narrow areas of bearing parts, reducing the possibility to metal-to-metal contact during the machinery operation, which causes wear of the bearing parts. What is the Lube Hybrid Lubrication (LHL) system? LHL is a lubrication system that is as friendly to manufacturing as is to the environment. Comparison between an oil lubrication system and the LHL system in terms of CO2 emission and power usage The graph on the left-hand side indicates that approximately 233 kg of CO2 is emitted per year per machine when a standard oil lubrication system is used: Electrical power consumption is shown in the graph on the right-hand side. These numbers are calculated by crude oil refinement, lubricant disposal and pumping power usage. With the LHL system, CO2 emission and power consumption of the machines are drastically reduced. Please note, however this value is just one example. 233kg 18kg 0.9kw Oil LHL Oil LHL CO2 emission Power usage (kg/year) 250 200 150 100 50 0 (kg/year) 25 20 15 10 5 0 92% reduction 96% reduction 23kw 1 LHL System LHL System Lube Hybrid Lubrication
Transcript
Lube Corporation was founded in 1964 primarily by developing and manufacturing centralized lubrication systems of industrial machinery manufacturers.
For more than a half a century, we have been developing centralized lubrication equipment and lubricants which are best suited to satisfy the needs of various types of industrial machinery. We have been working closely with and listening to a wide range of industrial machinery manufacturers and users globally in hopes our future products not only meet but exceed their expectations.
Together with our Global LUBE Team, we are committed to serving our customers as well as the manufacturing industry with the highest quality products and our exceptional customer service for the next 50 years and beyond. Our globalization which has been accelerating rapidly over recent years, will allow us to achieve this goal while caring for the future of our global environment.
October 2016Eijiro Horikoshi Chief Executive Officer
Purpose of the LHL systemOur corporate mission is to solve the problems that have remained outstanding on the boundary between machine manufacturers and machine users over many years. The problems in their respective specialized areas which we are referring to here are automation and machinery maintenance at manufacturing sites, as well as the protection of the global environment. We aim to integrate these problems and solve them by introducing the LHL system, and support our customers to achieve the desired levels of productivity, maintainability and environmental consciousness.
We have been developing the LHL system in cooperation with machine users and machine manufacturers by listening to their opinions, worries and concerns about saving limited resources all over the world.
Features and target of the LHL systemOur high-quality and highly reliable LHL lubricant has very high film thickness retention, load-carrying capacity and interfacing properties. It is able to spread over narrow areas of bearing parts, reducing the possibility to metal-to-metal contact during the machinery operation, which causes wear of the bearing parts.
What is the Lube Hybrid Lubrication (LHL) system?LHL is a lubrication system that is as friendly to manufacturing as is to the environment.
Comparison between an oil lubrication system andthe LHL system in terms of CO2 emission and power usage
The graph on the left-hand side indicates that approximately 233 kg of CO2 is emitted per year per machine when a standard oil lubrication system is used: Electrical power consumption is shown in the graph on the right-hand side. These numbers are calculated by crude oil refinement, lubricant disposal and pumping power usage. With the LHL system, CO2 emission and power consumption of the machines are drastically reduced. Please note, however this value is just one example.
233kg
18kg 0.9kw
Oil LHL Oil LHL
CO2 emission Power usage
(kg/year)
250
200
150
100
50
0
(kg/year)
25
20
15
10
5
0
92%reduction
96%reduction
23kw
1LHL System
LHL SystemLube Hybrid Lubrication
Using the appropriate lubricant volume contributes to reduced maintenance costs, maintains cutting fluid performance and prevents its deterioration as well as unpleasant odours.The Lube cartridge eliminates the need to use drums or pails, thereby reducing lubricant management costs. Minimum automatic greasing volume and the Lube cartridge can keep equipment clean.The high-quality LHL grease ensures the long-term reliability of the lubrication system.The performance of bearing parts is maintained for a much longer time, reducing bearing parts replacement costs.
【Problem example 1】The customer had refilled oil every day, feeling that a lot of oil was consumed.【Solution example 1】
● after installing LHL system, refilling frequency became once every three to four months. This drastically reduces refilling time resulting in decreased labor requirements.
● by using a LUBE cartridge, the lubricant can be replaced simply and safely for everyone.
【Problem example 2】Because lubricant was getting mixed into the cutting fluid, the customer frequently had to replace the cutting fluid.【Solution example 2】The volume of lubricant mixed into the cutting fluid has been reduced, so that the maintenance and management can be done more easily. In addition, by using the oil skimming system, the cutting fluid did not need be replaced so frequently.
【Problem example 3】Lubricating oil had been mixed into cutting fluid which adhered to work pieces. The lubricating oil could not be appropriately removed from the work pieces with the washing machine in the following process. This led to a high rate of defects in the welding process.【Solution example 3】By modifying the existing oil lubrication system on the machines in the production line to LHL system, the volume of lubricant mixed into cutting fluid, as well as the welding defect rate were reduced.Furthermore, the washing fluid's performance is sustained for a longer period of time, reducing the frequency of washing fluid replacement.
Five major advantages with LHL system
1
1
2345
The appropriate lubricant volume contributes to reduced maintenance costs, maintains cutting fluid performance and prevents its deterioration as well as unpleasant odours.
【Problem example】The customer had to keep various different types of lubricating grease and oil in stock, and so had trouble keeping them in order.【Solution example】
● By using LHL system, multiple types of lubricants are no longer required. As a result, lubricant management has been simplified.
● Transporting pails and drums is no longer required.● Because anyone can replace the LHL cartridge, there is no
possibility of refilling the wrong lubricant.
2 The Lube cartridge eliminates the need to use drums orpails, thereby reducing lubricant management costs.
【Problem example】Because oil was spilled onto the floor while refilling, the floor had to be mopped every eight hours.【Solution example】With the Lube Cartridge, there is no potential for spills. This contributes to greater safety and efficiency of the workforce.
3 Minimum automatic greasing volume and theLube cartridge can keep equipment clean.
3.2L
Oil LHL
(L/year) 22L
2.5L
Oil LHL
(L/year)
Oil LHL
23.3times
4.5times
(times/year) 27.3times
Oil LHL
(times/year)
3.5times
Average replenishment frequency Average replenishment frequency
Average lubricant usage amount Average lubricant usage amount
Ordinary machining centers Ordinary lathes
Manufacturing Defects Frequency of cleaning-fluid replacement
Frequency of cutting fluid replacement
42L
Oil LHL Oil LHL
Oil LHL
50
40
30
20
10
0
25
20
15
10
5
0
25
20
15
10
5
0
(times/month)
25
20
15
10
5
0
(times/month)
2
1
0
(times/year)
2
1
0
30
25
20
15
10
5
0
92%reduction
88%reduction
80%reduction
87%reduction
50%reduction
90%reduction
50%reduction
2 LHL System 3LHL System
LHL SystemLube Hybrid Lubrication
Reasons why users and machine manufacturersinstall LHL systems
【Problem example】The customer was using grease with an inappropriate lubrication system, causing grease solidification and deterioration inside the system and bearing parts. This caused lubrication system failure and machine stoppage.【Solution example】Three years since upgrading to LHL, there have been no stoppages due to grease solidification or deterioration.
Since 2008 after LHL system was introduced, there have been no instances of solidification or deterioration found in any machine tools using LHL all over the world.There are 49,000 LHL systems in operation, globally, as of September 2016
4 The high-quality LHL grease ensures the long-term reliability ofthe lubrication system.
【Problem example】Pre-greased bearing parts were malfunctioning after roughly three years.【Solution example】Six years after installing LHL, the original bearing parts are still in operation.
The customers were facing various lubrication-related problems before adopting the LHL system that has solved them.LUBE is committed to constantly working with our customers to find solutions to the complex problems of the industry. LUBE considers the customers environment and conditions of their machine tools to provide the best solution for any lubrication problem.
5 The performance of bearing parts is maintained for a muchlonger time, reducing bearing parts replacement costs.
Please make sure to use LHL cartridge grease. The use of other grease may cause significant lossor damage to the lubrication systems and key moving components of your machines.
Above graph shows lubrication problems from a variety of customers from 2008 to 2016and how they have been improved by using LUBE LHL systems.
The Lube cartridge eliminatesthe need to use drums or pails,
thereby reducing lubricantmanagement costs.
2%
Low volumes of lubricantrequired reduces maintenance
costs and increases cutting fluid life.Reduced offensive odors
make a more pleasantwork environment.
49%
Other
5%
The high-quality LHLgrease ensures
a long-term reliablelubrication system.
8%
Cleaner equipmentdue to lower volumesof required lubricant.
15%
The performance of bearing parts is maintainedfor much longer time, so costs for the
replacement of bearing parts are reduced.
21%
● Pressure monitoring systems are available.● Compared to ordinary grease, LHL gives superior resistance to thermal increases.
Degree of centrifugal oil separation (25℃, 20,000 rpm)
Time (min)Re
sidu
al o
il co
nten
t (%
by
mas
s)
100
80
60
40
20
00 20 40 60
LHL-X100
Li complex grease
Li grease
※Note: The results of the centrifugal oil separation degree test indicate that the residual o i l content in LHL-X100 (urea-based thickener) is higher, suggesting that LHL-X100 is less susceptible to oil separation than lithium grease or lithium complex grease.
Oil LHL
Service life of mechanical parts(ball screws)
(year)
6
4
2
0
Over 2-fold improvement
4 LHL System 5LHL System
LHL SystemLube Hybrid Lubrication
South America 0.2%
Specialpurposemachine
8%Polishing machine 6%
Loader 5%
Automatic lathe 3%
Washing machine 2%
Laser-processingmachine 1%
Drilling machine 1%
Cutter 1%
Grinding machine 2%
Other processing machine 2%
Press 2%
Die casting machine 3%
Loader 4%
Europe 0.3%
India 1.9%
China 2.0%
U.S.A.13.1%
Southeast Asia23.9%
Japan58.6%
Automatic lathe8% Lathe
23%
Other9%
Machining center44%
Machining center32%
Lathe12%
Grindingmachine
11%
Actual results by region Actual results by type of machine
Number of LHL systems installed by machine manufactures
What is the LHL Eco-Upgrade?The LHL Eco-Upgrade is our initiative intended to eliminate problems with the existing lubrication systems attached to our customers' machines.By discussing and cooperating with each individual customer to find the best solution, we carry out this initiative by accurately targeting the relevant bearing parts and operating conditions.※Note: Depending on the operating conditions for the each machine, we may suggest another lubrication system layout.
"LHL eco UPGRADE" logo
Total number of LHL Eco-Upgrade between 2008 and September 2016
Total number of LHL systems adopted for machine tools between2008 and September 2016
What is the appropriate volume of lubricant for bearing parts?
Refer to “Standard discharge volume and interval for LHL centralized lubrication system” for the first time to consider the volume. The volume of lubricant and the length of interval time should be adjusted according to the operating condition of the machine.
In order to suggest the appropriate lubricant volume which is suitable for the operating condition of the machine, LRA (LUBE Real Analysis) is used to check the lubricating condition of LHL while the machine is running.
Between soft grease and hard grease, which is more suitable when bearing parts are subjected to cutting fluid?
In cases of automatic greasing with little greasing volume and short interval time, soft grease is appropriate because it has high flow-ability. In cases of manual greasing with much greasing volume and long interval time, hard grease is appropriate because it has high retentivity.
The LHL-X100 has high water resistance. This property reduces lubrication failure caused by cutting fluid which washes away the lubricant.
Is it possible to replace the pre-filled grease (NLGI No. 2) in the bearing parts which was originally delivered from the manufacturer by just connecting LHL system?
The pre-filled grease can be replaced with the LHL grease. However, we would suggest using EH1 grease for initial lubrication of bearing parts before shipping the machine.
Because the EH1 grease has a high level of affinity for the LHL grease, it prevents lubrication problems that may occur immediately after the machines are brought into service and allowing the LHL system to maintain its performance.
I would like to know how to maintain cutting fluid's performance.
It is important to control the concentration and pH of the cutting fluid. Mixing of lubricating oil into the cutting fluid can be the cause changes in the concentration and pH, so it should be avoided wherever possible.
To minimize mixture of lubricant into the cutting fluid, we use LRA to find the appropriate amount of lubricant which is suitable for customer’s machine.
Lube's commitment
Lube's commitment
Lube's commitment
Lube's commitment
6 LHL System 7LHL System
LHL SystemLube Hybrid Lubrication
The design properties were proactively adopted during and after the development and design phase. Saving space, low weight and harmonization with the design of various other machines were also considered.
Efforts toward future goalsWe review the internal parts and mechanism of the pump to prevent it from stopping due to air getting caught in the pump or because of foreign particles.We are also making efforts to achieve a longer service life compared to conventional pumps and to improve the pump's reliability.
A sample ladder diagram of recommended controls is available. Please contact us directly for more information.
VUC-IIcontroller for Eco-UpgradeA shift from conventional oil lubrication to LHL can be performed without modifications to NC. Please contact us directly for more information.Power supply voltage: 100‒240 VAC(50/60Hz)
Installation example of the LHL system for machine tools Components of the highly reliable LHL system and the metering valve
① Electric pump for LHL P-207
② Pressure gauge PB250
③ Metering valve MU-10
④ Pressure switch GPL-30-D
⑤ Junction MUJ-5S
⑥ Polyamide hose PH-60
⑦ Nylon tube NT-4
⑧ Cartridge grease LHL-X100-7
No. Description Modelseries pump designated for LHL
These small-sized, highly reliable valves use straight threads and optional push-to-connect tube fittings, so that they can be easily connected to the junction parts simplifying tubing work.
Metering valves designated for LHL
Pre-made custom assemblies for automatic lubrication systems
S series, MU typ Junction for MU-type small-sized metering valves
We can pre-assemble the tubing parts used in the lubrication system to suit the individual customer's machinery, and then deliver the system as one unit.Please contact your LUBE Global Network for more information.
⑥
④
⑧
①
②
⑤③
⑦
8 LHL System 9LHL System
LHL SystemLube Hybrid Lubrication
LHL-X100-7(700ml)
LHL performance testing data (operating temperature range: Between -20℃ and +150℃)
LHL-X100-2(200ml)
The LHL-X100 special urea grease provides thicker film than Li soap grease does in the low-speed region.We conducted a study with a focus on oil-film thickness, which we deemed essential lubrication performance. The study results indicated that oil-film thickness in the region in which rolling speed was 0 m/s (approximate to 0 m/s) was the thinnest.In general, grease has thicker film than oil does. The results also established that the special urea grease addressed in the present study provided thicker film than the widely used lithium grease did, showing that by using the special urea grease, it would prevent oil-film discontinuity.
Friction coefficient test (anti-stick-slip performance)The LHL-X100 produced no stick-slip at any speeds of testing.This suggests that the special urea structure and additives allowed this lubricant to form a lubricating film on the metal surface more securely even in the low-speed region than the high-grade sliding surface oil did, as well so as to prevent metal-to-metal contact.
1. Assessment method ● Fafnir test (compliant with ASTM D 4170)2. Test conditions ● Bearing: ANDREWS W 5/8 (2sets were used.) ● Load: 2,450N (Contact pressure: 1,861MPa) ● Angle of oscillation: 12°(Average rolling velocity: 0.065m/s) ● Oscillation cycle: 25Hz ● Duration: 22h ● Temperature: 25℃ ● Amount of grease applied before test: 1.0 ± 0.05g/bearing set ● Wear loss measurement: Reduction in bearing race mass per bearing set (Total mass reduction for all bearing races tested/2)
Test method 1. Tester: Bowden tester 2. Test conditions ● Material: Steel and steel ● Temperature: Room temperature ● Load: 4kgf ● Velocity: 3, 6, 24, 30, 60, 240, 600mm/min
Fafnir test results
General-purposelithium grease
High-performancesliding surface oil
Coe
ffici
ent o
f fric
tion
Coe
ffici
ent o
f fric
tion
μmax: Coefficient of static frictionμmin: Coefficient of dynamic friction
μmax: Coefficient of static frictionμmin: Coefficient of dynamic friction
High-performancesliding surface oil
LHL-X100
Sliding velocity (mm/min)There was stick-slip at a speed of 24mm/min or less.
Sliding velocity (mm/min)There was no stick-slip at any speeds.
0.2
0.15
1
0.05
0
Wea
r los
s (m
g)
1.2
1
0.8
0.6
0.4
0.2
0
1 10 100 1000
1 10 100 1000
μmax
μmin
μmax
μmin
LHL-X100
EH1 grease‒Lubricant forinitial lubrication of bearing parts foruse with the LHL grease
Featuresand
intended use
LHL-W100-7 (700ml)
The EH1 grease is a lubricant made of high-performance special urea intended for initial lubrication of bearing parts.It is insusceptible to heat and is not easily washed away by water.These properties prevent the lubricant from dripping or leaking from bearing parts during grease filling, machine assembly and transportation, offering lubricant retain-ability and rust protection.Also the EH1 grease has a high level of affinity for the LHL grease, it prevents lubrication problems that may occur immediately after the machines are brought into service and allowing the LHL system to maintain its excellent lubrication performance and functionality.
EH1 (400ml)
High-quality and highly reliable LHL cartridge greaseSpecial urea-based liquid grease for machine tools derived fromLube's long experience and expertise
LHL-W100 and LHL-X100 have different consistencies. If you are thinking about using LHL-W100, please contact us directly.
The EH1 grease is intended specifically for initial lubrication of bearing parts. Do not use it for any other purpose.The Lube hand grease gun LG400 is available to apply the EH1 grease.
LHL-X100 vs. LHL-W100 property comparison data
Test item
AppearanceColorWorked penetrationDrop point [℃]Copper corrosion (100℃, 24h)Evaporation loss(99℃, 22h) [% by mass]Oil separation (100℃, 24h) [% by mass]Oxidation stability (99℃, 100h) [kPa] LNL WL N LWIThickenerBase oil viscosity (40℃) [mm2/s]NLGI No.
AppearanceColorWorked penetrationDrop point [℃]Copper corrosion (100℃, 24h)Evaporation loss(99℃, 22h) [% by mass]Oil separation (100℃, 24h) [% by mass]Oxidation stability (99℃, 100h) [kPa] LNL WL N LWIThickenerBase oil viscosity (40℃) [mm2/s]Base oil viscosity indexNLGI No.
Semi-fluidYellow
460180
Pass*0.31N/A
512361569480
Special urea114.0
97000
Test item Property
‒‒
JIS K2220 7.JIS K2220 8.
JIS K2220 9.B JIS K2220 10. JIS K2220 11. JIS K2220 12.
Property comparison data between the LHL-X100 for centralized automaticlubrication and the EH1 for initial lubrication
Typical property comparison table
Typical property comparison table
Centralized automaticlubrication of machine tools
and other industrial machineryInitial lubrication
of various bearing parts
* No change in color into green or black on copper plate is observed.* No change in color into green or black on copper plate is observed.
* No change in color into green or black on copper plate is observed
Load-carrying capacityMeasured inHigh Speed 4 Ball Test
Load-carrying capacityMeasured inHigh Speed 4 Ball Test
406183
0.29
12361569496
00
Cen
ter fi
lm th
ickn
ess
(nm
)
Rolling velocity (m/s)
LHL-X100Special ureaLi #000Base greaseOil #110
1,000
100
100.001 0.010 0.100 1.000
Basic oil-film thickness assessment test
Fretting resistance test (results of the Fafnir test)
Load
Oscillation
10 LHL System 11LHL System
LHL SystemLube Hybrid Lubrication
The United Nations (UN) adopted the Globally Harmonized System of Classification and Labelling of Chemicals (GHS). The GHS includes criteria for the classification of health, physical and environmental hazards, as well as specifying what information should be included on labels of hazardous chemicals as well as safety data sheets.
■ What is the Globally Harmonized System of classification and Labelling of Chemicals (GHS)?・The GHS is a system intended to ensure that chemicals are classified by hazard type and hazard level in accordance with
globally standardized rules. It is also intended to ensure that this information is indicated on labels so that it can be understood at a glance, and that safety data sheets (SDS) containing this information are provided.
・The GHS requires local manufacturers and importers to prepare and distribute the labels and SDS in the local official language(s).
■ Development of the GHS around the world・GHS regulations and practices have been made law in countries where the GHS has been adopted, as well as countries
due to adopt GHS regulations.・Enforcement and the scope of obligations differ from country to country to maintain consistency with domestic laws.
■ The Lube cartridge grease falls under the category of chemicals, and is therefore subject to GHS regulations.
Compliance with GHS
GHS(Globally Harmonized System of Classification and Labeling of Chemicals)
Labelling items are globally standardized.
GHS-compliant labelling for Lube products
Lube Corporation is committed to complying withGHS regulations while delivering its cartridge greases worldwide.
Lube GHS compliance label (for use in the U.S.)
GHS compliance classification and labeling (pictograms)
For more information about the Lube global network, please visit our Web site.
http://lube-global.com
Labelling items1. Information related to chemicals2. Pictograms3. Alerts4. Hazard statements5. Precautions6. Manufacturer/importer informationNote: Additional items may be required depending on the country.
Labelling item 1Product name: LHL-X100-7Product code: 249137Product lot No.: 6L＊＊＊＊＊MPrecaution : NEVER REFILL THE CARTRIDGE. DO NOT REMOVE THE CARTRIDGE UNTIL IT BECOMES EMPTY.Country-specific code: US
Labelling items 2 to 5GHS classificationGHS hazard statements, and Precautions
The contents of the aforementioned information are based on the SDS (safety data sheet) issued by the manufacturer of the lubricant.
Labelling item 6Local manufacturer/importer information (address and telephone No.) Country of manufacture
Flame(for fire hazards)
Exploding bomb(for explosion or
reactivity hazards)
Gas cylinder(for gases under pressure)
Skull and crossbones(can cause death or
toxicity with short exposure tosmall amounts)
Health hazard(may cause or
suspected of causingserious health effects)
Exclamation mark(may cause
less serious health effects ordamage the ozone layer)
Environment(may cause damage to
the aquatic environment)
Corrosion(for corrosive damage to
metals, as well as skin, eyes)
Flame over circle(for oxidizing hazards)
12 LHL System 13LHL System
LHL SystemLube Hybrid Lubrication
LHL SystemLube Hybrid Lubrication
Keeping machinery running all over the world
Global Network
Head OfficeHorizon Bldg-1, 3-30-16 Nishi-Waseda, Shinjuku-ku, Tokyo, 169-0051 JapanTEL: (03) 3204-8431 (Switchboard) FAX: (03) 3204-8520
German subsidiaryKAA-Europa GmbH
Chinese subsidiaryLUBE LUBRICATING SYSTEM(SHANGHAI)Co.Ltd.
Vietnamese subsidiaryVL SERVICES Co. Ltd.
India subsidiaryLUBE AUTOMATICSYSTEMS Private Ltd. Thai subsidiary
