journal - lubrication journal edition 2/2008 speciality lubricants – how a small investment makes...
TRANSCRIPT
Lubrication is our world
JournaL E D I T I O N 2 / 2 0 0 8
Speciality lubricants – how a small investment makes the difference
Improving energy efficiency with synthetic gear oils
Challenging lubrication require-ments in pneumatic components
Comfortable driving and reliable car functions
Investing in economic efficiency State-of-the art speciality lubricants contribute to economic
success, or: How a small investment makes the difference
Improving energy efficiency Improving efficiency through the use of the right gear oil
Good chemistry makes for sound operation Cooperation between lubricant and component manufacturers
plays a vital role: an example from the field of pneumatics
If everything runs smoothly, you’re driving with Klüber You don’t see them, you don’t smell them – speciality lubricants
enable comfortable driving and reliable vehicle functions
Maximum precision, innovative technologies and international standards A guided tour through the production facilities of
Klüber Lubrication in Munich
Meet us at our trade showsWhite lubricants for white shipsNew brochures
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Contents
POTENTIAL SAVINGS
GEARS
PNEumATICS
AuTOmOTIVE
BEHIND THE SCENES
NEwS, SERVICE
2 T r i b o j o u r n a l 2 / 2 0 0 8
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At this time of turmoil in the global markets, which is affecting the eco-nomic development worldwide, a number of things have been subjected to review lately, not only in the financial sector. There is a growing will to ven-ture onto new paths.
But it is not always radical change that is called for. Many well-known tools, such as process optimisation, stringent cost management, innova-tive product ideas, etc. offer a sizeable potential for sustainable improve-ments. Klüber Lubrication is a consis-tent user of these techniques, but not just that: with our synthetic speciality lubricants, individualised tribological solutions and services, we offer sup-port to our customers, always with the focus on their economic benefit. Whether we are talking about extend-ing maintenance intervals in a produc-tion plant two-fold, or even more, hence saving resources; whether we are talking about avoiding unplanned machinery downtimes as a conse-
Dear reader,quence of poor lubrication, saving energy costs by means of significantly better machine efficiency, making inventories leaner by streamlining product ranges or reducing disposal costs with the help of minimum-quantity- or lifetime lubrica-tion: money spent on speciality lubricants made by Klüber is money invested in an overproportional increase in reliability and cost reduction. For more details, please read our article “Investing in economic efficiency” on page 4.
Also the other articles in this edition of Tribojournal provide information on what Klüber lubricants have to offer that goes far beyond their apparent principal task – i.e. reliable lubrica-tion. We would be very happy if we could inspire you with new ideas in your search for optimisation potential in your field of activities.
I wish you interesting reading,
Claus Langgartner
Claus Langgartner
Speaker of the Board
Klüber Lubrication München KG
The most recent lubricant developments
contribute to eco- nomical and successful
plant and machine operation. Be it the lip
of a tool, rolling or plain bearings, compressors or gears: taking a close look at lubrication and
unveiling new poten-tials always pays off.
4 T r i b o j o u r n a l 2 / 2 0 0 8
State-of-the-art speciality lubricants contribute to economic success, or: How a small investment makes the difference
Investing in economic efficiency
iceberg, e.g. costs for stoppages, maintenance, energy, spare parts, storage, disposal and of course lubricant con-sumption.
Synthetic speciality oils prove their efficiency when it comes to gear lubrication, for instance. Mineral oils should be changed after 5,000 operating hours, while synthetic, polyglycol-based gear oils like the Klübersynth GH 6 series can last for 25,000 operating hours or more, not only be-cause of their improved ageing resistance, but also because they show high load-carrying capacity and low friction values. The potential for cost savings of synthetic oils is even more impressive if gear maintenance and gear effi-ciency are included in the cost-benefit analysis. (You will find an informative article on this issue in Tribojournal 1/2008).
When it comes to bearing lubrication, Klüber speciality greases also ensure extended maintenance intervals. The savings potential can be illustrated by an example from the wind energy sector: If a turbine’s generator bearing has to be replaced after five years due to under-performing
Regarding the lubricant as an invest-ment in economic efficiency rather than just as a commodity, pays off in many ways. Of course, the price of the lubricant is an important factor, but it is more important to look at the en-tire cost-benefit calculation of a given application. If synthetic high-per- formance lubricants tuned to the particular application are used, the total cost of operation decreases. Such lubricants help to save costs even though their purchase price is higher than that of standard lubri-cants, as the price is just the tip of the iceberg. The real cost, and hence the potential for cost savings can only be detected at second glance. The term “Return on Lubricant” expresses the profitability and the amortisation of synthetic speciality lubricants and contains the submerged part of the
lubrication, the resulting costs are considerable. Mainte-nance work and lost profit, in addition to costs for personnel and materials can quickly add up to 6,000 Euros. If we assume that a turbine’s lifetime is approximately 20 years, the total maintenance cost is 18,000 Euros. If a suitable synthetic speciality grease, like Klüberplex BEM 41-141, is used, only the purchase price must be paid.
High-performing greases can even ensure lifetime lubri-cation of bearings so that relubrication becomes unneces-sary and already in the design, cost savings can be gener-ated, as relubrication facilities need not be included in the construction.
Another important cost factor is energy. Synthetic special-ity lubricants decrease the electrical current consumption compared to mineral-oil based lubricants, e.g. when used for the lubrication of compressors or gears. The efficiency increase can amount up to 18 % due to the improved friction behaviour of synthetic oils. (We shall be glad to provide test results on request.) The energy savings generated lead directly to lower operating costs.
It is also important to regard the lubricant as a machine element just like rolling or plain bearings and gearwheels whose quality contributes to the performance capacity of plants and machines. If the lubricant is unable to live up to the requirements of a particular application over the speci-fied time, there will be trouble ahead. Unscheduled stop-pages can incur substantial costs due to lost production, personnel costs and wasted materials. Lubricants tuned to the application at hand help to avoid such costs. They are instrumental for trouble-free operation of plants and machines.
Speciality lubricants also help to combine economic and environmental-friendly operation. High-performance lubri-cants tailored to a particular application facilitate reliable low- or minimum-quantity lubrication while making efficient use of energy and therefore contribute to conserving resources.
It makes no sense, therefore, to purchase a particular lubricant just because of its price, but rather to look at the total benefits it provides. Looking at the cost-benefit calcula-tion with particular regard to performance capacity and con-sumption, it often turns out that the higher-priced lubricant is by far the more lower-cost option.
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Return on Lubricant High-performance lubricants offer economic advantages, e.g. by offering
reliable operation of components, plants and machines
long maintenance intervals
performance increase
high energy efficiency
low lubricant consumption
processes which conserve resources
less used lubricant disposal
low inventory costs
Purchase cost
Lubricant consumption
Disposal cost
Downtimes
Cleaning costs
Energy consumption
Storage
Maintenance
Lubricant costs are just the tip of the iceberg. The real costs – and thus the savings potential – are not visible at first glance.
Ing. Mag. (FH) Florian Held
Head of Sales Austria Klüber Lubrication Austria Ges.m.b.H.
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industrial sector, the lubricant selected for use in the gear-box must be chosen for optimum performance under a specific set of operating conditions.
In the US market, Klüber has found that most OEMs tend to prefer the so-called H1 products for the sake of simpler logistics. The synthetic gear oils Klüberoil 4 UH1 N and Klübersynth UH1 6 are high-performance gear oils regis-tered as H1, with the added benefit of being food-grade. Thus, they can be employed in both food and industrial environments. It is important to note that standards for food-grade gear oils are just as high as for other gear oils, and the synthetics perform better than standard min-eral oils.
With regard to energy efficiency, some gear oils perform better than others due to their lower coefficient of friction. Polyglycols, for example, absolutely shine as the most efficient and lowest wear type of oils, particularly in high-sliding applications such as worm and hypoid gears.
Typically, end users rely on their OEMs to determine and recommend the best gear oil, so it is important for OEMs to value gear oil as a machine element much in the same way that they value hardness of the gears, bearing selection, materials and geometry. Like all of these other phys-ical components of a gearbox, the right gear oil will allow the gearbox to achieve optimum performance. As a result, end users will enjoy the benefits of lower wear rates, lower operating temperatures and, best of all, greater energy efficiency.
Synthetics are Best
Whether a gearbox is designed for use in a food manufacturing environ-ment, in a conveyor or in any other
Improving energy efficiency… through the use of the right gear oil
Many factors come into play when select-
ing gear oils, including the projected life of a gearbox, its seals and
the desired perfor-mance of the gearbox within an application.
After all, the right gear oil can contribute to
optimum gear perfor-mance: users will bene-fit from long oil change
intervals and lower energy consumption,
for example.
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In these applications, PAGs offer a lower coefficient of fric-tion within the gearbox, resulting in less power loss.
Synthetic oils have better oxidation and thermal stability, which means the gear oil lasts much longer. One could expect to change a mineral oil every 5,000 hours, whereas PAOs (synthetic hydrocarbon oils) can last approximately 15,000 hours before a change-out. In addition, PAGs can last as long as 25,000 hours at the same temperature.
As you can see, how often a manufacturer is required to change gear oil depends on the chemistry of the lubricant being used. The slope of the lines in graph x represents what is known as the 10K rule. The 10K rule dictates that for every 10 degrees you increase the temperature of the lubricant, you halve its performance life.
Also, remember that oxidation causes degradation of oil over time. The Total Acid Number changes, and the addi-tives are being used up. While changing the gear oil replen-ishes these additives and removes wear materials, it also adds maintenance downtime to the equation. Choosing a high-performance gear oil from the start will automatically reduce the amount of oxidation within the oil and decrease the required number of oil changes and downtime for equip-ment maintenance.
For OEMs, gear oil affects several design considerations, including the reliability of their final product. How much a manufacturer will increase the energy efficiency of a gear-box by using high-quality gear oil depends on the gear type.
The biggest increase can be realized in gear types that are challenged in normally lower efficiencies such as worm drives. Klüber’s worm gear test rig runs at approximately 60 percent efficiency with a mineral oil. With the PAO gear oil Klüberoil 4 UH1 4 N, efficiency goes up to 70 percent and with the polyglycol oil Klübersynth UH1 6 it rises to 78 percent. As the efficiency increases, the temperature of the gear box drops. This decrease in temperature increases the life of the gear oil, the seals and the gearbox as a whole. This may not sound like a big deal if you have one or two gearboxes in your plant, but if you have hundreds of gear-boxes, then that energy usage really adds up.
In summary, most OEMs and end users find that the extra cost of high-quality gear oil is worth the investment and that synthetic oils are proven to be the best. By choosing high-quality synthetic gear oil, end users will save energy and reduce operating costs through reduced maintenance and longer oil change intervals.
Mark Crombie
Manager of Application Engineering Klüber Lubrication North America LP
Fig. 2: Friction coefficients of different base oils
Mineral oill PAO/ester Polyglycol
Fig. 1: Expected oil life as a function of temperature
Oil
sum
p te
mp
erat
ure
°C
Oil
sum
p te
mp
erat
ure
°F
Operating hours
Mineral oil PAO/ester Polyglycol
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Not only are the development phases for new components becom-ing shorter and shorter – the products have to meet more stringent require-ments as well. Components are expected to fulfill several functions at the same time, they must not pollute the environment, and at the end of the day production costs should be lower than before. The lubricants involved are expected to function without prob-lem over a long time, in many cases over the whole lifespan of the compo-nent. This is only possible if they have been tuned carefully to the tribological system as a whole and the application environment in which they are to be used.
Pneumatic drives and control sys-tems pose taxing requirements in this respect. They incorporate a variety of different elements such as cylinders,
motors or valves, which are in turn made of different mate-rials, so the tribological system that results is often highly complex. Their operational reliability and service life are strongly influenced by the contact between the sealing element and the moving components, mostly made of metal, for example the piston rod or the cylinder wall. A
Cooperation between lubricant and component manufacturers plays a vital role: an example from the field of pneumatics
Good chemistry makes for sound operation
It is a frequent occurrence in many
sectors of industry that component develop-
ments are stalled because material
specialists were not involved at an earlier
stage. A lubricant, for example, that was
selected without checking if it matches
the particular tribo-sys-tem encountered in the component, may cause
unpredictable prob-lems and additional
costs when the compo-nent is put into opera-
tion. Such problems can easily be avoided if
the design engineer and the lubricant
specialist cooperate at an early stage.
Customers can then benefit from compo-
nents that function reliably with reduced
operating costs.
Factors influencing the tribo-system of a sealing system
Static sealing sideMounting tolerance
System pressure
Sealing material
Ambient temperature
Gap width Guide clearancel
Surface layers in contact
Pressure and pressure behavior
Casing material
Dynamic sealing side
Medium to be sealed
Direction of motion Standstill time
Contamination form outside
Contamination/water in the medium
Sliding speed Stroke frequency
Micro-geometry “Roughness”
Pressure and pressure behavior
Opposing surface Friction temperature
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a H
erna
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ixel
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decisive factor for maximum service life and proper func- tion is the right pre-start lubrication of all components that move relative to one another, e.g. piston rod, cylinder wall, valve slide and sealing elements. Furthermore, the lubricants used for reducing friction and wear must also be tuned to the ambient temperature, sliding speed and normal forces, just to name a few.
When pneumatic components fail during operation, the ensuing costs can be substantial – the repair costs for the pneumatic unit can by far exceed the costs of a lubricant that is precisely tuned to the component/tribo-system used, or the replacement of a failed seal. As operating pressures, temperatures, sliding speeds and stroke frequencies rise continuously, the points where shafts or rods are taken through housing walls have proven the most critical areas for design engineers and tribologists.
Taxing conditions
Selecting a speciality lubricant that suits a particular design and application of pneumatic components takes a lot of expertise and knowledge of tribology. There is a variety of factors that influence the processes in the various gaps and spaces that make up the tribological system:
intermolecular forces
thermal transmission and conduction
friction and wear
chemical and electro-chemical corrosion.
These factors must be considered while bearing in mind:
cylinder and rod materials
different seal materials and sealing lip geometries
contact surface pressure and surface micro-geometry
acting pressures
mounting position and situation.
Additionally, there are various environmental factors acting on the component and the friction point, e.g. low and/or high temperatures or aggressive media in liquid, gaseous or abrasive form, such as sand, etc. Only an early coopera-tion between design and tribology engineers leads to the development of sound products that truly benefit the cus-tomer.
Oil-tight means less energy consumption
A major requirement in the development of pneumatic components is the prevention of leakage. While a compo-nent is in operation, some leakage may go unnoticed, for example when water leaking from a pump evaporates on the spot. There are less trivial types of leakage, though, which have to be remedied with considerable outlay in terms of time and costs. Compressed air, for instance, is expen-sive to generate and leaks therefore extremely costly. There is a rule-of-thumb saying that you have to reckon one to two Euro-cents for each cubic metre of compressed air generated. Each additional bar of compressed air can be expected to increase energy costs by approx. 10 %. This means costs can rise enormously, especially when leakages go unnoticed, e.g. in connecting lines, check- and control valves, quick-fit joints, maintenance units or the terminal equipment. Besides professional maintenance, it is high-quality design elements, namely in terms of the materials used, sealing elements and lubricants, that are indispens-able for economical operation, with replacements becoming necessary only at long intervals or not at all. Consequently, when looking at the costs what matters is not so much the cost of air compression as such, but rather how much ener-gy is needed to make the compressed air available at the point of use. On average, approx. 33 % of compressed air is generated only to vanish through a large number of small leaks which combine to a significant loss.
An example calculation visualises the losses to be ex-pected – and hence the potential for improvement: A me-dium-sized company operates a 100 kW compressor sta-tion with a total runtime of all compressors of approx. 6 000 hours a year. Based on a power tariff of 6.5 Euro- cent per kWh the annual energy costs to be spent on compressed air will amount to approx. Euro 39 000. If the typical leakages can be prevented, the operator will need 30 % less compressed air, resulting in savings of roughly Euro 12 000 on energy alone.
Complex pneumatic components are very demanding in terms of lubrication
10 T r i b o j o u r n a l 2 / 2 0 0 8
Oil-tight over 6 000 kilometres
Klübersynth AR 34-402, a synthetic special grease for pneumatic drives and their seals, underwent a lifetime test with highly convincing results. The following parameters had been used for the test:
Mounting position: horizontal Cylinder type: VDMA cylinder Compressed air: dry and de-oiled
Temperature: + 20 °C
Pressure: 8 bar
Speed: 1 m/s
Load: 0 kg mass at the rod
Power reduction: none
Targeted distance: at least 6 000 km
The test was performed without a transverse load to prevent wear on the guide influencing the friction results.
A well-known measure for the durability of pneumatic seals is the amount of leakage occurring after a certain operating time. The Pneuko M test cylinders from Merkel-Freudenberg Fluidtechnic showed no significant wear after 6 500 km. The pneumatic cylinders were checked for leak-age throughout the test duration. No leakage was detected even after 6 000 km. Only after approx. 6 500 km, some minor leaks of approx. 0.6 l/h on the piston side and approx. 0.9 l/h at the rod side were detected.
The synthetic special grease Klübersynth AR 34-402 is highly adhesive and free of heavy metals or solid lubricants. It contains a package of active substances that is carefully tuned to the range of possible applications, making for excellent, balanced product performance combined with high operational reliability and a long service life.
Klübersynth AR 34-402 is frequently used for pneumatic control and sealing elements such as in ISO single- and double-acting cylinders with and without piston rods, in pneumatic rotary drives, short-stroke and compact cylin-ders, valves as well as the associated sealing elements. Be-sides a relatively wide service temperature range of at least – 30 °C to +130 °C, piston speeds of approx. 0.01 m/s to > 1 m/s are possible – sufficient service life was attained even exceeding 5 m/s. Further characteristics are minimum breakaway torques that help to prevent the so-called “Monday morning effect” after prolonged standstill as well as stick-slip, which is a plus when piston speeds are low, and during positioning.
Klübersynth AR 34-402 has proven its worth in combina-tion with piston-, rod- and dampening-seal profiles of various shapes and materials, such as NBR, HNBR and PU mate-rials. Klübersynth AR 34-402 can be easily applied using the known methods and metering equipment. For pneumatic
control or sealing elements with special geometries, the grease is also available in the softer NLGI consistency class 1 (Klübersynth AR 34-401) to ensure that all friction points are sufficiently wetted.
Combined know-how
To prevent leakages from being caused by brittle seals, it is essential that the seal and the lubricant be compatible. The companies Merkel Freudenberg Fluidtechnic and Klüber Lubrication, both members of the Freudenberg Group, have been engaged in a close cooperation in the field of pneumatic components for many years. This cooperation also involves well-known manufacturers of pneumatic elements and re-search institutes of universities. Klüber Lubrication and Merkel Freudenberg Fluidtechnic offer their mechano-dyna-mical test rigs for tests that replicate application and com-ponent realities as near as possible. The combined know-ledge of all the specialists involved enables the development of seal-and-lubricant combinations for the various tasks encountered in pneumatic systems. Their operators will eventually benefit from the sophisticated design of the pneu-matic drives, the valves and their seals. They can trust their machinery to operate reliably over a long time and cut their energy costs considerably.
Helmut Seubert
PM Technical Elements and Machines Klüber Lubrication München KG
A scenario like this is largely a thing of the past, and this is not least due to the development of tailor-made high-performance speciality lubricants that
are individually tested for each and every component. Lube points in cars that are greased, oiled or coated can be counted by the hundreds. Speciality lubricants help to reduce friction and wear, and in addition they damp oscil-lation and vibration and prevent noise – which makes for a pleasant, high-quality feel when handling the lubricated components. In brakes as well as in the steering assembly, engine peripherals, gear shift, clutch, gears,
Brakes, steering assembly, engine peripheral compo-nents, gear shift, clutch and gears, doors, sun-roof and all kinds of interior components – lubricating greases, pastes and bonded coatings are to be found anywhere in a car. However, as they are designed accord-ing to the motto “You don’t see them, you don’t smell them”, they not only ensure that the individual compo-nents last throughout a car’s life, but they also make for more com-fortable driving.
“What a way to start a day… It’s six o’clock, still dark and freezing cold. I’m off to work. My car’s parked by the street-lamp.
Fumbled the key from my pocket, pressed the remote button and – what a nasty surprise – no familiar clicking sound, nothing at all. I push the key in the lock. I can’t turn it, the lock has frozen up. Go back into the house, get a lighter. Heating the key with the flame, I burn my fingers. I try the lock again, and finally the buttons pop up.
I want to get in, but the door won’t open. The seal is stuck to the metal. I give it a good yank and get inside eventually. But something’s wrong: right, my daughter drove the car last night. Pushing back the seat, cranking up the back rest – how arduous! Now jerk the steering column into position, and readjust the outside mirror. Insert the key, turn it by 90 degrees, now things should move. Slowly, the mirror grinds into place. Finally I push up the head rest, another act of sheer force!
Now everything’s in place and I reach for the belt. I sin-cerely hope the return spring hasn’t frozen up. Pulling hard, I manage to fasten it.
It’s high time I left! I push the clutch pedal down all the way, and turn the ignition key. The battery just makes it and the engine comes on with a whining sound, no doubt the neighbourhood’s wide awake now. Engage first gear, let in the clutch – and off we go!”
You don’t see them, you don’t smell them – speciality lubricants enable comfortable driving and reliable vehicle functions
If everything runs smoothly, you’re driving with Klüber
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doors, sunroofs and components inside the car – lubricants are used everywhere and have the task to make compo-nents last throughout the car’s life.
Just as there are highly different components and machine elements, there are also different lubricants for a wide variety of applications. For the selection of the right lubricant, it is essential to have a thorough understanding of the specific requirements to be met by the individual components. A large number of factors such as temperature range, influ-ence of media, relative motion of the lubricated parts, rota-tional speed, the materials used and the loads placed on the friction bodies are to be taken into account. Less-than-opti-mal lubricants can provoke premature wear on the compo-nents, e.g. due to insufficient lubrication or undesirable chemical reactions. Most certainly, the driving comfort will be affected.
Tailor-made
For the automotive sector alone, Klüber has developed far more than a hundred different lubricating greases, pastes and bonded coatings, many of them tailored to individual applications in close cooperation with the OEMs. A good example is one of Klüber’s most recent innova-tions: Klübersynth LE 44-31. This grease was specifically developed to meet the requirements encountered in elec-tric power steering systems (EPS) and attains very low fric-tion coefficients in worm gears. Owing to its good wear protection properties, Klübersynth LE 44-31 permits tight compression of the worm against the wheel so that there is no clearance between the two parts during the entire life-time. Furthermore, substantial energy savings can be generated due to the grease’s high efficiency. In this way Klüber also supports car designers in their efforts to reduce vehicle emissions.
Comfortable driving
Nowadays, car users have become less tolerant of annoying noises inside their cars. A perfectly smooth ride is no longer considered a privilege of the luxury car seg-ment. Klüber has developed the special greases of the Klübersynth RA 44 series to prevent noises caused by vibration and friction as well as the squeaking sometimes heard when actuating ventilation knobs or sun visors. These damping greases also help to attain a smooth sen-
Comprehensive testing
Klüber invests a large amount of research and testing in the development of lubricants that meet the customers’ requirements. The company has more than 100 test rigs designed to determine the compatibility and performance characteristics of each individual lubricant, by means of tests according to DIN ISO standards and tests made specifically for original components and materials. As safety considerations always play a role in the automotive industry, these efforts are fully justified: only with the right lubricant can the trouble-free operation of all components be ensured through-out the specified lifetime.
Development partnerships
Through cooperation of component- and lubricant manufacturers at an early stage, innovative solu-tions for automotive applications can be found. Klüber supports the ideas of engineers developing car components by providing tribological solutions for new materials and material pairings as well as extended performance requirements.
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sation when adjusting armrests or seat rails, or operating switches. Since they are available in a variety of apparent dynamic viscosities, designers can use them to compen-sate for tolerances in their components and precisely determine the actuating forces required. Klübersynth RA 44 greases are neutral in odour, offer versatile uses and excel by their good compatibility with plastics.
Had Klübersynth LIP 84-42 been available at the time of the scenario described above, the driver would have had to face fewer difficulties. This special grease was devel-oped for components that can be exposed to very low temperatures over an extended period of time, e.g. electric window lifters. Klübersynth LIP 84-42 enables heavily loaded components to run smoothly over a wide tempera-ture range. It was developed for the critical material pair-ings plastic/plastic and plastic/metal, so it ensures reliable operation of sliding shoes in slide rails, or of turn rollers and bolts, even at temperatures far below zero.
Many more examples could be listed; lubricants made by Klüber are today found in all parts of motor vehicles – everywhere around the world. Klüber products have gained a large number of approvals from car manufacturers and suppliers. Among the products that have been tried and tested in series applications are: speciality lubricants for brakes, steering systems, axles, CV joints, engine periph-erals, gear shift, clutch, electric equipment, the car interior, locks, window lifters, sun roofs, seats, safety belts and profiled seals. So when everything in a car functions smoothly, it may very well be that Klüber has had its part to play.
Ing. (grad.) Josef Bartolome
Business Unit Automotive Engineering Klüber Lubrication München KG
Your development partner for innovative lubrication solutions
Whether for by-wire technology, exhaust gas recirculation or applications in the car interior, we regard lubricants as major design elements. Renowned component and car manufacturers worldwide count on Klüber as a development partner and provider of genuine high-tech solutions. We use advanced testing technology at an early development stage, where possible on the original component, to ensure future-oriented solutions for maximum quality and economy. If you want your ideas to gather momentum why not call us.
for your ideas
m mentum
Klüber Lubrication – present [email protected] www.klueber.com
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mance in many respects. The base oils are delivered according to a carefully designed schedule to ensure opti-mum raw material availability at all times.
The base oils are pumped from the tanks to the produc-tion facilities through an extensive pipe network as required by the production schedule. There is a separate line for each type of base oil to prevent undesirable mixing. This is par-ticularly important since Klüber Lubrication manufactures sometimes small volumes of speciality lubricants that are tai-lored to the specific requirements of a customer.
Other lubricant ingredients are delivered in various types of containers: the high-lift storage racks in the warehouse are packed with drums, canisters and sacks, each at a computer-assigned storage location. One rack is reserved for small containers. It contains substances that are needed in small quantities for very special lubricant preparations, e.g. special products for individual customers requiring only one or two small shipments each year. The smallest volume that Klüber Lubrication produces as part of their standard range is no more than 50 kilograms. The whole spectrum of raw materials selection and purchasing applies to these small quantities as well – from the material specifications to sup-plier selection and to quality inspection on incoming goods.
The “ingredients” for a lubricant are collected from the shelves by the warehouse staff using a checklist. They are
When guiding groups of visitors through Klüber’s production section at Munich, Production Manager Dr. Andreas Martin starts the tour away from the actual production facilities because he likes to begin his explana-tions with what the manufacturing pro-cess is based on: the raw materials. The bulk component of the lubricants
– the base oil – is delivered to Klüber’s raw materials warehouse by tank trucks and filled into large storage tanks. Today, Klüber makes the major-ity of its lubricants on the basis of syn-thetic oils, which offer better perfor-
The production of speciality lubricants is
a process that requires utmost precision:
which substances are to be added in what
quantity is accurately laid down in the manu-facturing instructions.
But this is only one aspect of the manufac-
turing process at Klüber Lubrication.
Many factors come into play to ensure that lubricants made by
Klüber can be obtained with the same high quality level world-
wide.
A guided tour through the production facilities of Klüber Lubrication in Munich
Maximum precision, innovative technologies and international standards
Base oils are supplied via underground tanks
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various small-sized containers are filled in a separate pro-duction sub-section: these can be ½- and 1 kg cans, 400 g grease cartridges, 1 l canisters, 20 ml bottles and many more.
Dr. Andreas Martin concludes the tour of the manufactur-ing facilities at Klüber Lubrication in Munich pointing out that visitors could have witnessed the same processes at the production sites in Mysore, Querétaro or Salzburg: Klüber speciality lubricants are produced at 15 production sites worldwide, each according to the same standards. Klüber has production sites in Argentina, Belgium, Brazil, Germany, India, Italy, Japan, Korea, Mexico, Austria, Spain, Turkey, the USA, and, since March 2008, China. This is where the Group’s youngest production plant was commissioned in the Shanghai Qingpu Industrial Zone, approximately 40 kilo-metres from Shanghai city centre.
then forwarded to the production hall. To avoid confusion, a single production employee is always responsible for the whole production process of a lubricant batch, from taking over the raw materials from the warehouse right down to filling the finished lubricant into containers, and even to cleaning the kettles.
“The first step when making a grease”, explains Dr. Martin, “is the manufacture of the thickening component, the so-called thickener.” Klüber Lubrication make their own thick-eners for their greases, a process which involves some chemical reactions. To make sure that these reactions take place exactly according to plan, the staff need to have the required technical knowledge and have to adhere meticu-lously to the process instructions. Large kettles with spe- cial stirrer mechanisms are used for lubricant production. The technology used for the kettles is developed by Klüber’s engineering department, and all of Klüber’s production sites worldwide use it as a standard. This is necessary to ensure that Klüber lubricants can be manufactured to a constant quality standard worldwide – a prerequisite for successful global player business with international customers. If kettles are of different shape or have walls of different thickness, the temperature curves during production may vary, which can eventually affect the characteristics of the finished lubricant.
When the thickener is ready, base oil and additives are added. The additives, in particular, must be weighed ac-curately before they are added: they serve to “refine” the lubricant, i.e. they impart the desired high-performance characteristics. Once all substances have been added, the mixture is stirred until it is homogeneous. This is a seemingly simple process, but it ensures that each gram of lubricant has the same composition of substances.
There is a special production room that is reserved for machinery processing those special lubricants where maximum homogeneity and purity are essential – e.g. those applied in minimal quantities: the rolling bearing in a computer fan receives just 0.06 grams of a lubricant! In such applications, even tiny impurities or deviations in vis-cosity can cause problems in operation, e.g. noises in a CD drive.
During the whole production process, samples are taken and tested to monitor the product quality. All test results are documented and archived. This ensures a constant high lubricant quality, and the causes of any problems can be eliminated.
Finally, the finished speciality lubricant is filled into drums, canisters or buckets, depending on what the customer requested. This is done under constant supervision. Klüber lubricants can also be obtained in small packages. The
Certifications
At Klüber, both the quality of the lubricants and the production standard stand up to any test. Klüber Lubrication not only complies with “normal” stan-dards such as ISO 9001 or ISO 14001, but also with less common norms such as OHSAS 18001 relating to occupational safety. What matters most to Klüber is the individual wishes and requirements of its cus-tomers and their sectors of industry – as is demon-strated by certifications according to ISO TS 16949 as well as numerous customer awards.
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Colombiatex de las Americas 27 – 29 January 2009Medellín, Colombia
SEPEM 27 – 29 January 2009Douai, France
ITMEX 10 – 13 March 2009São Paulo, Brazil
CFIA 10 – 13 March 2009 Rennes, France
MAINTEC 18 – 20 March 2009Birmingham, UK
MOTION ENGINEERING JAPAN 15 – 17 April 2009 Chiba, Japan
Hannover Messe 20 – 24 April 2009 Hanover, Germany
Arminera 28 – 30 April 2009 Buenos Aires, Argentina
Mach Tech 8 – 10 May 2009 Budapest, Hungary
ChinaPlas 18 – 21 May 2009 Guangzhou, China
Djazagro 18 – 21 May 2009 Algiers, Algeria
MSV 19 – 22 May 2009 Nitra, Slovakia
AUTOMOTIVE ENGINEERING EXPOSITION 20 – 22 May 2009 Yokohama, Japan
Fondex May 2009 Brno, Czech Republic
Istanbul Textile Machinery 6 – 9 June 2009 Istanbul, Turkey
WindPower – AWEA 7 – 10 June 2009 Minneapolis, USA
INTERNATIONAL FOOD MACHINERY & TECHNOLOGY EXHIBITION 9 – 12 June 2009 Tokyo, Japan
Shanghai Textile 12 – 15 June 2009 Shanghai, China
FISPAL 15 – 18 June 2009 São Paulo, Brazil
Exhibitions: Platforms for contactsuse these opportunities for a personal talk: we look forward to meeting you at our stand, for example at the
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You will find a comprehensive overview of exhibitions attended by Klüber under www.klueber.com/News/Exhibitions etc. – just click and have a look!
ProPak Asia 17 – 20 June 2009 Bangkok, Thailand
Mechanical Components & Materials Technology Expo 24 – 26 June 2009 Tokyo, Japan
SEMICON Japan 24 – 26 June 2009 Chiba, Japan
Swiss Alpina 26 – 28 August 2009 Martigny, Switzerland
EXPOMAN 1 – 4 September 2009 Recife, Brazil
FENASUCRO 1 – 4 September 2009 São Paulo, Brazil
Alihankinta 8 – 10 September 2009 Tampere, Finland
Extemin 14 – 18 September 2009 Arequipa, Peru
MSV 14 – 18 September 2009 Brno, Czech Republic
drinktec 14 – 19 September 2009 Munich, Germany
CanWEA 20 – 23 September 2009 Toronto, Canada
Process Expo 5 – 7 October 2009 Las Vegas, USA
TIB 7 – 11 October 2009 Bukarest, Romania
Maintain 13 – 15 October 2009 Munich, Germany
CFIA 20 – 22 October 2009 Metz, France
TOKYO MOTOR SHOW 23 October – 8 November 2009 Chiba, Japan
Andinapack 3 – 6 November 2009 Bogotá, Colombia
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Cruise ships are holiday resorts floating upon the sea, surrounded by water, the wind and the waves. It is there-fore vitally important not only to ensure a maximum of safety for the vessel and its passengers, but also to convey them a feeling of neatness, cleanliness and safety. The visual impression of the ships plays a major role in this context. The lifeboats, for example, are an obvious eye-catcher when it comes to considerations of safety. A dark, graphite-containing lubricant sticking to the ropes, shackles and pulleys may fulfill its purpose func- tionally, but certainly is not a pretty sight – and even less so when it’s dripping onto the deck below. Of course it’s not only the looks but also the reliable function of the men-tioned components that depend on the lubricant. The con-ditions encountered at sea, involving salt water, tropical to arctic temperatures and constant strain, are extremely challenging. Klüber Lubrication have developed Klüberplex AG 11-462, an adhesive lubricant with high load resistance, which not only has no problem coping with the requirements at sea, but ensures also clean looks on board, e.g. on the lifeboat decks, due to its light colour. Klüberplex AG 11-462 was developed as an operating and priming lubricant for
Automotive
Industrial sector brochure “Driving with Klüber – Speciality lubricants for automobiles”
Bearings
Product selection brochure “A selection of special lubri-cants for rolling bearings”
Product selection brochure “Speciality lubricants for the initial and additional lubrication of sintered metal bearings”
open gear drives and offers very good adhesion even at high temperatures as well as an excellent lubricating and anticorrosive effect, even when exposed to salt water. That, and the fact that it’s white, makes Klüberplex AG 11-462 the obvious choice for applications on cruise ships, e.g. for the lubrication of wire ropes, pulleys and open gears. Klüberplex AG 11-462 also extends relubrication intervals, which helps to reduce lubricant consumption and costs.
Machine tools
Special knowledge brochure “Producing to plan”
Product selection brochure “Special lubricants for cutting machine tools”
Wind energy
Special knowledge brochure “Always with the breeze”
Product selection brochure “Special lubricants for wind turbines”
White lubricants for white ships
New Klüber brochures
Tribojournal
Publisher and CopyrightKlüber Lubrication München KG Geisenhausenerstraße 7 81379 München – Deutschland phone +49 (0) 89 / 78 76-0 Fax +49 (0) 89 /78 76-333E-mail: [email protected]
Edition 02.2008 / TJ082002
Reprints, total or in part, are permitted only prior consultation with Klüber Lubrication München KG and if source is indicated and voucher copy is for- warded.
The contents of these articles are based on our general experience and knowl-edge at the time of printing. They serve for general information only and can be no substitute for expert consulting. We therefore do not accept liability for any damage resulting from using information gained from these articles. Any informa-tion given on Klüber products does not constitute an assurance of product prop-erties or of a product’s suitability for a particular application. Our competent staff will be pleased to support you by consulting you in all matters regarding lubrication. If required and possible we will be pleased to provide a sample for testing.
Local first-instance court Munich, GermanyCertificate of registration 46624
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Last but not least …
Are you interested in finding out more about some of the topics discussed in this Tribojournal? Please let us know on which subject you wish to receive more detailed information, and we will provide you with the relevant documentation.
Would you like to receive the Tribojournal regularly?
Our customer journal appears twice a year, and we will be pleased to supply you with a free copy – either electronic or as a hardcopy. The Tribojournal is available in English, German, French and Spanish. You can submit your subscription for the journal in any of these languages on the Klüber website www.klueber.com, Service > Order brochures > Tribojournal.
Contact:We would welcome any feedback, proposals, questions or requests in connection with the Tribojournal. Please contact our editorial team via
e-mail: [email protected] orFax: +49 (0 )89 / 78 76 - 9 05 04.
White lubricants for white ships
New Klüber brochures
we are where you are.
Klüber Lubrication – the world market leader
in specialty lubricants
• subsidiaries in over 30 countries• more than 1,700 staff• products available worldwide
Klüber Lubrication offers expert tribological solutions.
Through our worldwide presence, we meet customers’
needs reliably and on time. We supply tailor-made specialty
lubricants to customers from nearly all branches of industry
and around the world – oils, greases, bonded coatings,
pastes and many more. Over 75 years of experience,
industry-specific know-how, and exceptional test facilities
all help to optimize our solutions.
www.klueber.com
Klüber Lubrication München KGA company of the Freudenberg Group