 What is an air oil lubrication system?

The air oil lubrication system is a fascinating lubrication method that combines the power of
compressed air and oil to provide efficient lubrication for machinery. It is essential for experts
to be knowledgeable about various technical aspects of this system. Firstly, they should
understand the components involved, such as the air-oil mixer, lubrication unit, and
distribution network. They should also have a comprehensive understanding of the system's
operating parameters, including air pressure, oil viscosity, and flow rates.

 air-oil mixer

1. the air-oil mixer, a fascinating piece of engineering marvel! This remarkable

contraption is responsible for creating the perfect blend of compressed air and oil in
an air oil lubrication system. Picture it as a masterful mixologist, skilfully combining
the elements to concoct a lubricating elixir for your machinery.
2. The air-oil mixer typically consists of several essential parts. Firstly, there are the air
and oil inlet ports, where compressed air and lubricating oil enter the mixer. These
ports are equipped with valves or regulators to control the flow rates of air and oil.
Next, we have the mixing chamber, where the magic happens. It's designed to allow
intimate contact between the air and oil, facilitating thorough blending.
3. To achieve the desired air-oil ratio, the mixer may employ various techniques. One
common approach involves using a Venturi nozzle, which utilizes the pressure
difference between the high-velocity air stream and the surrounding oil to mix them
effectively. Another method utilizes precision orifices to regulate the flow rates and
achieve the desired proportions.
4. Once the air and oil are mixed in the right ratios, the resulting air-oil mixture exits
the mixer through an outlet port. From there, it travels to the lubrication unit, which
further controls and distributes the mixture to the lubrication points of the
machinery.
5. The design and construction of air-oil mixers can vary depending on the specific
application and system requirements. It's important to ensure that the mixer is
properly sized and calibrated to deliver the appropriate air-oil mixture for optimal
lubrication performance.
6. Remember, the air-oil mixer plays a crucial role in creating the perfect lubricating
blend, ensuring smooth operation and longevity of your machinery.

 lubrication unit

1. The lubrication unit consists of several key elements, each serving a specific purpose.
Let's dive into its inner workings, shall we? First and foremost, we have the reservoir, a
chamber that stores the lubricant, be it the air-oil mixture or any other suitable
lubricating fluid. The reservoir capacity may vary depending on the application, and it
is designed to provide a steady supply of lubricant.
2. To regulate the flow of the lubricant, the lubrication unit incorporates various
mechanisms. One such mechanism is a pump, which creates the necessary pressure
to propel the lubricant through the distribution network. The pump can be driven by
an electric motor, pneumatic power, or even manual operation, depending on the
specific system requirements.
3. To ensure precise control over the lubricant delivery, the lubrication unit often
features valves, regulators, and flow meters. These components allow for adjustments
in flow rates, pressure, and timing, enabling customization to suit the machinery's
lubrication needs.
4. Additionally, the lubrication unit may incorporate filters or strainers to remove any
impurities or contaminants present in the lubricant. This helps maintain the
cleanliness and integrity of the lubrication system, preventing potential damage to
the machinery.
5. The lubrication unit is typically connected to the air-oil mixer or lubricant supply
through suitable piping or tubing. It acts as a central hub, receiving the lubricant and
distributing it to the lubrication points throughout the machinery via a network of
pipes, tubes, or channels.
6. Proper maintenance of the lubrication unit is crucial to ensure its optimal
performance and longevity. This includes regular inspection, cleaning, and lubricant
replenishment as per manufacturer guidelines. It is also important to monitor and
adjust the unit's settings, such as flow rates and pressure, to meet the specific
lubrication requirements of the machinery.
7. With its vital role in delivering the lifeblood of lubrication, the lubrication unit keeps
your machines running smoothly, reducing friction, wear, and prolonging their
operational life.

 distribution network
1. The distribution network is designed to facilitate the smooth flow of the lubricant from
the lubrication unit to the targeted lubrication points throughout the machinery. It
comprises a network of interconnected pipes, tubes, or channels that transport the
lubricant with precision and reliability.
2. The design and layout of the distribution network depend on the specific machinery
and lubrication requirements. It is crucial to ensure proper sizing, routing, and
positioning of the distribution network to effectively reach all the lubrication points
while minimizing pressure drops and flow restrictions.
3. To ensure efficient lubricant delivery, the distribution network often incorporates
various components. These can include flow control valves, fittings, connectors, and
junctions, which enable proper regulation, branching, and routing of the lubricant
flow. Additionally, the network may utilize separators or filters to remove any
impurities or debris present in the lubricant, safeguarding the machinery from
potential damage.
4. The distribution network is typically configured to deliver the lubricant to critical
lubrication points, such as bearings, spindles, gears, or any other components that
require lubrication. It ensures that the lubricant reaches these points in the
appropriate quantities and at the desired pressure, allowing for smooth operation,
reduced friction, and extended component life.
5. Proper installation and maintenance of the distribution network are essential. It
involves regular inspections to identify and address any leaks, blockages, or damage
that may hinder the lubricant flow. The network should be periodically cleaned and
flushed to remove accumulated contaminants or debris that could impede the
lubricant delivery.
6. By efficiently channelling the lubricant to every corner of the machinery, the
distribution network ensures that no vital component goes thirsty for lubrication. It
keeps the wheels of your machinery turning smoothly and extends their performance
and reliability.

 Air Pressure:
1. Air pressure refers to the pressure of the compressed air used in the lubrication
system.
2. The appropriate air pressure ensures the proper atomization and distribution
of the air-oil mixture or lubricant.
3. The recommended air pressure may vary depending on the specific application
and machinery requirements.
4. Maintaining the correct air pressure is essential to achieve optimal lubrication
performance and avoid issues like inadequate lubricant coverage or excessive
misting.
 Oil Viscosity:
1. Oil viscosity is a measure of the oil's resistance to flow and its thickness or
consistency.
2. It plays a critical role in determining the lubricant's ability to form a protective
film and reduce friction between moving components.
3. Different machinery and operating conditions may require specific oil viscosity
grades to ensure adequate lubrication.
4. Choosing the right oil viscosity involves considering factors such as operating
temperature, load, speed, and manufacturer recommendations.
5. Using oil with incorrect viscosity can lead to insufficient lubrication or
excessive oil film breakdown, affecting the machinery's performance and
longevity.
 Flow Rates:
1. Flow rates refer to the rate at which the lubricant or air-oil mixture is delivered
to the lubrication points.
2. Proper flow rates ensure sufficient lubrication coverage and replenishment to
the components in need.
3. The specific flow rate requirements may vary depending on the machinery's
design, component size, and lubrication demands.
4. It is important to balance the flow rates to avoid over-lubrication, which can
result in excessive oil consumption, leakage, or component damage, and
under-lubrication, which can lead to increased friction and wear.
 Monitoring and Adjusting:
1. Regular monitoring and adjustment of operating parameters are necessary to
maintain optimal lubrication performance.
2. It involves periodically checking and verifying the air pressure, oil viscosity,
and flow rates to ensure they align with the recommended values.
3. Adjustments may be required based on changes in operating conditions,
machine requirements, or as specified by the equipment manufacturer.
 4. Utilizing appropriate measurement devices and following manufacturer
guidelines are crucial for accurate monitoring and adjustment.

By understanding and carefully controlling these operating parameters, the

lubrication system can deliver the right amount and quality of lubrication, promoting
smooth machinery operation and extending equipment life.

 Usages
The usages and applications of the air oil lubrication system are widespread. It is commonly
employed in high-speed rotating equipment, such as bearings, spindles, and gears, where it
offers excellent cooling and lubrication properties. Additionally, it finds application in
industries such as manufacturing, automotive, and aerospace, where precise and efficient
lubrication is crucial for optimal equipment performance.

 How the system works

Here is a step-by-step breakdown of how the system works:
1. Compressed air is supplied to the system.
2. The air passes through a regulator, which controls the pressure.
3. The compressed air flows into a mixing valve, where it is mixed with oil.
4. The air/oil mixture flows through a distribution block and into a network of tubes.
5. Nozzles at the end of each tube spray the mist of air and oil onto the machine
components.
6. The mist lubricates the components, reducing friction and wear.

 How to install the system

To install the air oil lubrication system, follow this step-by-step procedure.

1. Begin by selecting the appropriate lubrication unit and air-oil mixer for your application.
2. Identify the lubrication points on the machinery where the system will be installed.
3. Install the air-oil mixer at a suitable location, ensuring proper alignment and connection to
the air and oil supply lines.
4. Connect the lubrication unit to the air-oil mixer, following the manufacturer's instructions.
5. Install the distribution network, consisting of pipes or channels, to deliver the air-oil mixture
to the lubrication points.
6. Ensure proper sealing and connection of all components, avoiding any leaks.
7. Test the system for proper operation and adjust the air pressure and oil flow rates as
needed.

 How is it different from other lubrication systems present?

 The air oil lubrication system differentiates itself from other lubrication systems in
several ways. Here's a table outlining the key differences and types of lubrication
systems:

Lubrication
System Differentiation from Air Oil Lubrication

Air oil system provides continuous lubrication, while grease requires

Grease periodic replenishment. Air oil lubrication is ideal for high-speed
Lubrication applications.

Air oil system uses compressed air to mix with oil, whereas oil mist
Oil Mist lubrication atomizes oil into fine droplets. Oil mist is more suitable for
Lubrication large-scale machinery and enclosed environments.

Air oil system provides a liquid lubricant, while dry lubrication uses
solid materials to reduce friction. Air oil lubrication is better suited for
Dry Lubrication high-load and high-speed applications.

Air oil system utilizes compressed air, while circulating oil lubrication
Circulating Oil employs a pump to circulate oil. Air oil lubrication is advantageous for
Lubrication its precise control and cooling capabilities.

Air oil system incorporates compressed air, while forced oil lubrication
Forced Oil relies on an external pump to deliver oil under pressure. Air oil
Lubrication lubrication offers better cooling and is more cost-effective.

 For long term maintenance of the system

 To maintain the air oil lubrication system for long-term operation, follow these
steps:
1. Regularly monitor the air pressure, oil flow rates, and system performance to
ensure optimal lubrication.
2. Conduct periodic inspections of the distribution network for any leaks or
blockages and address them promptly.
3. Regularly check the oil quality and viscosity and replace or replenish it as per
manufacturer recommendations.
4. Clean or replace air filters to maintain proper air quality and prevent
contamination.
5. Train personnel on system maintenance procedures and safety guidelines.
6. Keep records of maintenance activities, including oil changes, component
inspections, and repairs.
7. Regarding costs, it is important to consider factors such as initial installation
expenses, ongoing maintenance requirements, and the cost of consumables
like oil and air filters. The specific costs can vary depending on the size of the
system, equipment complexity, and industry factors.

How to choose the correct oil for your system

Selecting the correct oil for a system requires careful consideration of various factors.
Here are some key points to guide you in choosing the appropriate oil:
 Consult Manufacturer Recommendations:
1. Start by reviewing the equipment manufacturer's recommendations and
specifications.
2. Manufacturers often provide guidelines on the type of oil, viscosity grade, and
any specific additives required for optimal performance.
 Understand Operating Conditions:
1. Consider the operating conditions of the machinery, including temperature,
load, speed, and environment.
2. Higher temperatures may require oils with better thermal stability, while heavy
loads may necessitate oils with higher film strength.
3. Extreme operating conditions may call for specialized oils designed for specific
applications.
 Determine Viscosity Requirements:
1. Identify the viscosity range recommended by the manufacturer for your
equipment.
2. The viscosity grade should match the machinery's operating temperature
range and the required film thickness for effective lubrication.
3. Choose the oil with a viscosity that provides sufficient lubrication at the
anticipated operating temperatures.
 Consider Oil Additives:
1. Some applications may require additional oil additives to enhance
performance or provide specific properties.
2. Examples include anti-wear additives, corrosion inhibitors, detergents, or
dispersants.
3. Evaluate whether the system requires such additives based on the
manufacturer's recommendations and the specific application requirements.
 Check Compatibility:
1. Ensure that the selected oil is compatible with the system's seals, gaskets, and
other materials in contact with the lubricant.
2. Incompatible oils can lead to seal deterioration, leakage, or other performance
issues.
 Quality and Certification:
1. Choose oils from reputable manufacturers known for producing high-quality
lubricants.
2. Look for oils that meet industry standards and certifications, such as API
(American Petroleum Institute) or ISO (International Organization for
Standardization) certifications.
 Seek Expert Advice:
1. If you are uncertain or have specific concerns about oil selection, consult
lubrication experts or professionals in the field.
2. They can provide valuable insights based on their experience and knowledge
of similar applications.

Remember that selecting the correct oil is crucial for maintaining equipment
performance and longevity. By considering the manufacturer's recommendations,
understanding operating conditions, and seeking expert advice when needed,
you can make an informed decision regarding the best oil for your system.

 top 10 manufacturers of air oil lubrication systems in India:

1. Dropsa India Pvt. Ltd.

2. Bijur Delimon India Pvt. Ltd.
3. Lubsa Multilub Systems Pvt. Ltd.
4. Groeneveld India Pvt. Ltd.
5. Lubrication Engineers India Pvt. Ltd.
6. Hennex India Pvt. Ltd.
7. Oiltech Lubrication Systems
8. Lubrication Systems & Solutions
9. S.V.A Rikkon Lubes Private Limited
10. Lubrite Industries
These manufacturers are known for their high-quality air oil lubrication systems and excellent
customer service.