Conservación de la energía a través del uso de lubricantes especiales.
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Date
2025
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Publisher
Universidad de Concepción
Abstract
La presente investigación tiene como objetivo evaluar el ahorro energético asociado al uso de lubricantes con aditivos especiales en reductores de velocidad industriales, operando bajo condiciones reales de planta. Para ello, se diseñó una metodología dual: una teórica, aplicada al caso nominal del sistema, y otra experimental, basada en técnicas predictivas de mantenimiento enfocadas en el monitoreo de variables eléctricas, térmicas y vibracionales.
El estudio comparó el rendimiento de dos lubricantes ISO VG 220: Royal Purple Synergy 220 cSt y Mobil SHC 630 220 cSt. Los resultados teóricos evidenciaron que el lubricante Synergy 220 cSt permite reducir las pérdidas energéticas en un 18%, lo que se traduce en un incremento de eficiencia del orden de 1.38% a 1.54% en un reductor de tres etapas helicoidal.
No obstante, la validación experimental de estos resultados se vio limitada por dos factores clave: i) la presencia de diferencias vibracionales entre los equipos evaluados, y ii) la elevada incertidumbre del equipo de medición de corriente (SUPCO DVCV), cuyo error absoluto supera el umbral necesario para una validación estadísticamente confiable. Por tanto, aunque la hipótesis de lograr un ahorro energético superior al 3% se cumple teóricamente, no pudo ser confirmada de forma concluyente en condiciones de planta.
A pesar de estas limitaciones, el estudio demuestra el alto potencial del uso de lubricantes avanza dos como una herramienta efectiva para mejorar la eficiencia energética en entornos industriales. Esta línea de acción cobra especial relevancia en el marco de la Ley 21.305 sobre Eficiencia Energética, que obliga a grandes consumidores a implementar sistemas de gestión energética.
Como trabajos futuros, se propone la incorporación de instrumentación de mayor precisión en terreno, como el multímetro Fluke 289 con pinza i30 y sensores de vibración triaxiales. Asimismo, se sugiere el desarrollo o utilización de un banco de ensayos tipo FZG, que permita replicar condiciones controladas, estandarizadas y comparables para validar con mayor certeza el impacto real del lubricante sobre la eficiencia del sistema.
This study aims to evaluate the energy savings associated with the use of lubricants containing special additives in industrial speed reducers operating under real plant conditions. To achieve this, a dual methodology was developed: a theoretical approach applied to the system’s nominal case, and an experimental approach based on predictive maintenance techniques focused on monitoring electrical, thermal, and vibrational variables. The study compared the performance of two ISO VG 220 lubricants: Royal Purple Synergy 220 cSt and Mobil SHC 630 220 cSt. Theoretical results showed that Synergy lubricant can reduce energy losses by 18%, resulting in an increase in system efficiency ranging from 1.38% to 1.54% in a three-stage helical gearbox. However, the experimental validation of these findings was limited by two critical factors: (i) significant vibrational differences between the tested gearboxes, and (ii) the high measurement uncertainty of the current measuring device (SUPCO DVCV), whose absolute error exceeds the required threshold for statistically reliable validation. Therefore, while the hypothesis of achie ving an energy efficiency improvement greater than 3% is met in theoretical terms, it could not be conclusively confirmed under real operating conditions. Despite these limitations, the results highlight the high potential of advanced lubricants as a stra tegic tool for improving energy efficiency in industrial systems. This approach is particularly re levant within the framework of Chilean Law 21.305 on Energy Efficiency, which mandates large consumers to implement energy management systems. For future work, the implementation of more precise field instruments is recommended, such as the Fluke 289 multimeter with i30 clamp and triaxial vibration sensors for continuous monitoring. Additionally, the development or use of a closed-loop FZG-type test bench is proposed, allowing controlled, standardized, and repeatable conditions to better isolate and quantify the real impact of lubrication on system efficiency.
This study aims to evaluate the energy savings associated with the use of lubricants containing special additives in industrial speed reducers operating under real plant conditions. To achieve this, a dual methodology was developed: a theoretical approach applied to the system’s nominal case, and an experimental approach based on predictive maintenance techniques focused on monitoring electrical, thermal, and vibrational variables. The study compared the performance of two ISO VG 220 lubricants: Royal Purple Synergy 220 cSt and Mobil SHC 630 220 cSt. Theoretical results showed that Synergy lubricant can reduce energy losses by 18%, resulting in an increase in system efficiency ranging from 1.38% to 1.54% in a three-stage helical gearbox. However, the experimental validation of these findings was limited by two critical factors: (i) significant vibrational differences between the tested gearboxes, and (ii) the high measurement uncertainty of the current measuring device (SUPCO DVCV), whose absolute error exceeds the required threshold for statistically reliable validation. Therefore, while the hypothesis of achie ving an energy efficiency improvement greater than 3% is met in theoretical terms, it could not be conclusively confirmed under real operating conditions. Despite these limitations, the results highlight the high potential of advanced lubricants as a stra tegic tool for improving energy efficiency in industrial systems. This approach is particularly re levant within the framework of Chilean Law 21.305 on Energy Efficiency, which mandates large consumers to implement energy management systems. For future work, the implementation of more precise field instruments is recommended, such as the Fluke 289 multimeter with i30 clamp and triaxial vibration sensors for continuous monitoring. Additionally, the development or use of a closed-loop FZG-type test bench is proposed, allowing controlled, standardized, and repeatable conditions to better isolate and quantify the real impact of lubrication on system efficiency.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Mecánico/a.
Keywords
Maquinaria Lubricación, Lubricantes, Tribología