ROBOTICS & AUTOMATION USING LUBRICANTS AND OILS.
This is the First Part in our LUBRICATION EXCELLENCE Series, Series 2 Precision or Pressure discussing Grease Guns for Robotics
Robotics and automation systems require specialized lubrication and oil for their complicated components, such as joints, gearboxes, bearings, and linear guides, operate under specific, often extreme, conditions, which necessitate high-performance, specialized lubricants to ensure –
Precision and Repeatability: Lubricants must maintain consistent properties across temperature ranges to ensure accurate movement, Robots perform tasks with tolerances often measured by micrometers or verniers, feeler gauges or DTI (Dial Test Indicator ). Their precision depends on the mechanical integrity of components like gears, bearings, and joints.
Standard Lubricants: Can degrade, causing variations in friction or premature wear that lead to slight changes in backlash or position.
Specialized Lubricants: Are formulated to maintain a stable friction coefficient across operating temperatures, ensuring consistent and repeatable positional accuracy throughout the robot’s lifespan This is key for high-quality production in industries like electronics or automotive assembly..
Wear Protection: They need to withstand high loads, shock loads, and continuous, rapid motion.
Extended Service Life: High-quality lubricants extend maintenance intervals and prolong the life of critical, expensive components.
Specific Environments: Robots in food processing, cleanrooms, high-temperature areas (like welding),or vacuum environments require food-grade (NSF H1), low-outgassing, or high-temperature stable lubricants.
Robots on a production line face conditions that go beyond what general-purpose lubricants are designed for.
High Loads and Speeds: Robotic joints and gearboxes (especially RV and Harmonic Drive reducers) operate under intense pressure and rapid, repetitive movement. Specialized greases and oils have high load-carrying capacity and are formulated to prevent metal-to-metal contact even under these stresses.
- Temperature Extremes: Robots may operate near furnaces, welding stations (high heat), or in cold rooms Specialized synthetic lubricants maintain their viscosity and lubricating film strength across a wide temperature range, preventing thermal degradation or congealing (which can cause over-torque alarms).
- Continuous robots often run 24/7. Specialized lubricants, particularly synthetics, offer superior thermal and oxidation stability, leading to significantly extended drain/re-lubrication intervals (e.g., up to 24,000 hours), which maximizes uptime.
Application-Specific Requirements
Many industries have unique environmental requirements that demand specific lubricant properties.
Food & Pharmaceutical: Robots in these sectors require Food-Grade (H1-rated) lubricants that are non-toxic and compliant with strict safety regulations to prevent product contamination in case of incidental contact.
Cleanrooms (e.g., Electronics/Semiconductor): Need low-outgassing or non-shedding lubricants (like PFPE greases) to prevent airborne contaminants that could damage sensitive products.
Welding/Painting: Require lubricants that resist contamination from spatter or chemicals and offer long-term protection against corrosion.
Component Protection and Longevity
The mechanical components in a robot are highly complex and expensive. Using the correct, specialized lubricant is the most cost-effective way to protect that investment.
Preventing Wear: Proper lubrication minimizes friction and heat, directly reducing component wear and significantly extending the service life of critical parts like gearboxes, actuators, and bearings.
- Minimizing Downtime: Component failure due to improper lubrication is a leading cause of unplanned downtime, which can be immensely costly in a high-volume production line. Specialized lubricants ensure reliability, turning potential emergencies into predictable, planned maintenance.
THE INPORTANCE OF LUBRICATION AND OIL CHECKS/CHANGES IN A WELL BALANCED PPM (PLANNED PREVENTATIVE MAINTENANCE) PROGRAM.
It is critically important to have a very good Planned Preventive Maintenance (PPM) schedule, especially one that includes regular lubrication and oil checks, to keep both maintenance costs and equipment downtime to an absolute minimum. A proactive PPM strategy is a fundamental shift from costly reactive maintenance (fixing things after they break) to a more strategic, cost-saving approach. To this end it is vitally important to have a well stocked Lubrication Centre or Station which is also kept clean and all lubricants well labelled and also charts corresponding to particular machines/equipment and the relevant lubrication. This should be done prior to buying the equipment and after consultation with the OEM manufacturers. As well as been well stocked, it is important to keep plenty of grease guns or Oil jugs so as to avoid contamination, getting Personnel to keep a register of items used is also crucial to maintain stocks, this asset should come under a 5s mandate,
Planned vs. Unplanned Downtime: A good PPM schedule allows you to plan maintenance during non-peak hours, scheduled shutdowns, or low-production periods, this planned downtime is far shorter and less costly than a sudden, unplanned breakdown, which can halt production entirely and require rushed maybe expensive emergency repairs. By keeping critical components like bearings and gearboxes properly lubricated and free of contaminants, you significantly reduce the rate of wear, directly extending the functional life of your expensive equipment.
Controlling Costs
| Maintenance Type | Cost Impact | Downtime Impact |
| Planned Preventive Maintenance (PPM) | Lower – Maintenance is scheduled, parts can be ordered in advance, labour is predictable. | Minimal/Scheduled – Done during off-hours, resulting in high production uptime. |
| Reactive Maintenance | High – Emergency labour (overtime), expedited shipping for parts, potential secondary damage. | Unplanned and Extensive – Production stops until the emergency fix is complete, leading to significant revenue loss. |
Best Practices for Lubrication in Your PPM Schedule
A successful PPM program must prioritize lubrication management:
Use the Right Lube: Ensure the correct type and amount of lubricant is specified for each lubrication point on each asset, according to manufacturer recommendations.
Schedule Oil Analysis: Don’t just change the oil based on time. Oil sampling and analysis (a form of predictive maintenance) provides insights into:
Contamination: The presence of water, dirt, or other fluids.
Wear Debris: Microscopic metal particles that indicate which components are failing (e.g., iron for gears, copper for bearings).
Oil Health: Remaining useful life of the lubricant.
Establish Clear Routes & Intervals: Create specific routes and schedules for your technicians to perform lubrication tasks (daily, weekly, monthly, etc.) to ensure nothing is missed.
- Control Contamination: Use dedicated, clearly labelled storage and dispensing containers to prevent mixing different lubricants or introducing contaminants during the refill process.
In Conclusion, a robust PPM schedule with a strong focus on lubrication and oil analysis is your most effective tool for maximizing equipment reliability and minimizing long-term operational costs.
