Lithium grease is a widely used lubricant in industrial applications, offering excellent water resistance, high-temperature stability, and long-lasting lubrication properties. It is commonly found in machinery, automotive components, bearings, gears, and various other mechanical systems. Because lithium grease reduces friction and wear, it is critical for ensuring the smooth operation and longevity of equipment. As such, precise control over its application is essential in many industries.
For example: Recently Silver Automation Instruments receive below request for lithium grease flow measurement: We have an application where we are using a pneumatic pump to “dispense” lithium grease. (viscosity 220 cST) We need to measure the Volume 0.026 - 1.0 gpm with feedback to a PLC. Is this possible using your 4-20 feedback, concern for the pulsating action of the pump.
They need us to provide a suitable flow meter for his tough flow measurement application.
Why is Flow Measurement Important for Lithium Grease?
Accurate flow measurement of lithium grease is necessary to ensure the correct amount is applied during lubrication processes. Over-lubrication can lead to increased operational costs and equipment failure due to excess buildup, while under-lubrication results in insufficient protection, causing wear, damage, or premature breakdown of machinery. This is particularly important in automated lubrication systems, where grease is dispensed at predetermined intervals. Ensuring precise grease flow measurement in these systems ensures consistent and efficient lubrication.
In large-scale industrial operations, where machinery must run continuously and at high speeds, improper lubrication can lead to downtime, costly repairs, or even complete system failure. Accurate flow measurement also enables manufacturers to monitor and control the use of lithium grease, reducing waste and optimizing operational efficiency. For these reasons, the accurate and reliable measurement of lithium grease flow is crucial in maintaining equipment and reducing costs.
Challenges in Measuring Lithium Grease Flow
Lithium grease presents several challenges for flow measurement, largely due to its unique properties as a thick, semi-solid material. Some of the key difficulties include:
1. High Viscosity flow measurement needed: Lithium grease has a much higher viscosity than most liquids, the viscosity can be more than 200 cps, which means it does not flow as easily through pipelines and can be difficult to measure using traditional liquid flow meters,such as turbine flow meter, electromagnetic flow meter and so on . High viscosity also increases the risk of clogging or slow response times in flow measurement devices.
2. Variable Consistency: Depending on the formulation and temperature, the consistency of lithium grease can vary significantly. Low flow flow meters must be able to handle these changes without sacrificing accuracy or reliability.
3. Low Flow Rates flow meters are needed: In some applications, lithium grease is dispensed in very small quantities over long periods, for example, the min flow can only be around 100 ml/min, or 200 ccm, few flow meter can detect that low flow rate. This makes it essential for the flow meter to measure very low flow rates accurately, something many conventional flow meters struggle with.
4. High pressure flow meter is needed: The thick nature of lithium grease means that high pressure is often required to force it through the dispensing systems. Flow meters need to be capable of withstanding these pressures without becoming damaged or compromising measurement accuracy.
Working Principle and Advantages of Small Positive Displacement Flow Meters
Small positive displacement (PD) flow meters are highly effective for measuring the flow of lithium grease due to their ability to handle high-viscosity fluids and provide accurate measurements at low flow rates. The basic working principle of a PD flow meter involves trapping a specific volume of fluid in a chamber and then measuring how many times that chamber is filled and emptied as the fluid passes through the meter. This direct volumetric measurement makes PD meters highly accurate, regardless of the fluid’s viscosity or flow conditions.
For lithium grease, small PD flow meters offer several key advantages:
1. High Accuracy grease flow meter: Positive displacement flow meters are known for their precise measurements, even at low flow rates starts from 10 ml/min. This is essential for applications that require small quantities of grease to be dispensed consistently over time.
2. Viscosity Independence : Unlike some other types of flow meters, the performance of PD flow meters is unaffected by the viscosity of the fluid being measured. This makes them ideal for handling thick lubricants like lithium grease. It is a kind of high viscosity flow meter.
3. Durability: Positive displacement meters are designed to be robust and reliable made by stainless steel or aluminum, able to withstand the high pressures often required to move lithium grease through pipelines. Their durable construction ensures long-term accuracy and minimal maintenance.
4. Minimal Pressure Drop: Despite the high viscosity of lithium grease, small PD flow meters can operate with minimal pressure drop, ensuring the efficient flow of grease through lubrication systems.
5. Digital lithium grease flow meter: Low flow grease flow meter is powered by 24V DC, it is standard with PNP or NPN pulse output or analog 4-20mA output to connect with PLC. It is also option with digital display and micro flow meter with MODBUS RTU communications.
Silver Automation Instruments provides high-quality small positive displacement flow meters that are perfectly suited for measuring lithium grease low flow. These low flow flow meters are designed to handle the specific challenges associated with high-viscosity fluids like lithium grease, offering accurate and reliable measurements. In addition, Silver Automation Instruments offers these micro flow meters at factory prices, ensuring that customers receive excellent value without sacrificing performance or durability.
For industries that rely on the precise application of lithium grease, choosing the right low flow rate flow meter is critical. Silver Automation Instruments’ small PD flow meters provide the accuracy, reliability, and cost-effectiveness needed to ensure smooth and efficient operations, making them an ideal choice for grease lubrication systems.
