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Product category: Machine Safety Components
News Release from: Square Two Lubrication | Subject: Memolub HPS automatic lubricator
Edited by the Engineeringtalk Editorial Team on 28 November 2005

Automatic lubricator makes maintenance
safer

Square Two Lubrication's Memolub HPS lubricator and Matrix high-performance lubricant have been installed at Ford's Leamington foundry, thereby improving safety for maintenance personnel.

Providing effective, safe and economic lubrication for the large foundry run by the Ford Motor Company at Leamington spa in the UK proved to be a challenge, according to the plant's maintenance team The existing regime proved ineffective for various reasons: safety-critical areas of operation, the difficult working environment and the costly downtime witch led to lost production

The Ford maintenance team carried out a root-cause analysis and the resulting data called for a two-pronged attack against the problem.

The results showed the need for an advanced preventative maintenance system, incorporating condition monitoring, and a cost-effective, reliable method of lubrication.

The plant required a system capable of delivering lubricant in a precise controlled manner across a large number of bearings and other lubrication points.

The harsh environment associated with one of the country's busiest foundries also provided the team with other challenges.

Many areas provided little or no access for the safe performance of lubrication tasks.

The search for a reliable lubrication method revealed a number of potential alternatives.

Centralised lubrication systems were considered, but the systems on offer were deemed uneconomic due to the difficulty of installation and the provision of bespoke pneumatic systems.

Also the proposed installation and commissioning of these systems would require a lengthy line stoppage, and were therefore ruled out to safeguard production levels.

Single-point automatic lubricators were also considered.

But they were found to be unsuitable due to the inherent faults associated with this type of lubricator.

First the low-pressure discharge required the lubricator to be fitted directly to the lube point.

This raised safety concerns, as it meant plant personnel had to access the lube point directly in order to replace spent units.

This would also cause a loss of production as, in most cases, replacement would require the machine to be switched off.

The other main drawbacks of these systems were the inaccuracy of the discharge setting.

As these units work on a chemical reaction electrolyte and, in most cases, hydrogen gas, and are affected by changes in ambient temperatures.

Ford required an economic, multi-point, precise, reusable high-pressure lubrication system capable of remote installation.

It was during this search that Square Two Lubrication introduced the Memolub HPS automatic lubricator.

The Memolub HPS is a versatile, technically advanced, self-contained automatic lubricator.

Its patented design offered the exact specification to meet Ford's requirements.

The positive displacement pump ejects lubricant at an astonishing 350psi from the first stroke to the last.

When the Memolub HPS is turned on, it begins lubricating without delay.

The high lubricant ejection pressure opens a new range of applications not possible with other self-contained lubricators.

The ability to place the Memolub HPS remotely up to 12m from the lubrication point, and to lubricate up to eight lube points with a single lubricator, was a definite advantage.

The Memolub HPS is a precision Swiss-made machine.

Under normal operating conditions and with reasonable care, it is designed to last through many years of use.

A simple low-cost replacement kit is all that is required to use the Memolub HPS again and again with only seconds required to change the lube cartridge and battery pack.

Over the years, this can add up to substantial savings over the cost of manual lubrication - and 'throw away' lubricators - while providing assurance of the highest quality of lubrication.

Reductions in bearing replacement and equipment downtime alone can more than pay for the cost of the Memolub HPS and provide considerable savings as well.

Following a full plant survey in conjunction with Ford personnel, Square Two was able to provide an extensive lubrication plan detailing the sighting of Memolub automatic lubricators, installation schedule and discharge volumes for the correct lubrication of the wide variety on applications.

Once the method of lubrication was agreed, attention then turned to the specification of the lubricant itself.

Again the Ford maintenance team had high expectations.

They wanted to use one lubricant to cut out the risk of incorrect application and to simplify the amount of different products held on site.

Again, Square Two had the answer and introduced Ford to Matrix EP2.

Claimed to be unique, Whitmore's Matrix EP2 contains an exclusive blend of ingredients enabling superior performance in a wide range of operating conditions, and it is said to outperform conventionally manufactured lubricants.

It has excellent corrosion-, pressure- and water-resistance and can be considered for use in any situation where bearings, rollers or couplings require lubrication.

After proving trials were carried out on specific items of equipment, the decision was made to make Square Two Lubrication's Memolub HPS lubricator and Matrix high-performance lubricant the standard for Ford's Leamington facility.

A program of installation was agreed and, currently, Square Two Lubrication and The Memolub HPS now lubricate over 75 per cent of the plant effectively, consistently and safely.

This, coupled with the introduction of a monitored preventative maintenance system, has resulted in a reduction of unplanned bearing failures to zero.

Initially installed on No 7 line and rolled out onto the VFM department, the Memolub system was then expanded to the No 1 line, and finally rolled out onto the Melt Department - which is under way at present.

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