Grease manufacturing system and grease manufacturing method

Abstract

To provide a technology that can reconfigure manufacturing processes according to product specifications for grease.SOLUTION: A grease manufacturing system (100) that is an embodiment of a grease manufacturing system comprises a plurality of device units (1-11) for continuous grease manufacturing, and at least a part of the device units is portable.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a grease manufacturing system and a method for manufacturing grease.

Background Art

[0002] Patent Document 1 discloses a method for preparing urea grease, including steps of: (a) introducing a first supply component into a first supply zone; (b) introducing a second supply component into a second supply zone; (c) performing a first reaction mixture in a first reaction mixture zone; and (d) performing a cooling mixture in a cooling mixture zone.

[0003] In the method for manufacturing urea grease described in Patent Document 1, zones for performing supply, reaction, urea grease processing, etc. of various supply components are defined, and it is described that various urea greases can be obtained without significant changes in the process and apparatus.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, generally, grease is a small-batch and multi-variety product, and it is necessary to change the base oil of the grease, the types of thickener raw materials and additives, and the presence or absence of additives according to the required performance and application of the customer. Therefore, when using the same manufacturing equipment, sufficient cleaning is required due to the problem of contamination.

[0006] In addition, for some high-performance products, manufacturing in a special environment such as a clean room or dedicated milling equipment is required. Therefore, according to the availability of equipment, processes such as transferring containers within or between factories using small containers and reintroducing them to processing equipment are added, requiring the creation of a very complex manufacturing plan and the implementation of labor-intensive operations. As a result, the situation is prone to human error.

[0007] One aspect of the present invention aims to provide a technology capable of reorganizing a manufacturing process according to the product specifications of grease.

Means for Solving the Problems

[0008] To solve the above problems, a grease manufacturing system according to one aspect of the present invention includes a plurality of equipment units for grease manufacturing, and at least a part of the equipment units is portable.

Effects of the Invention

[0009] According to one aspect of the present invention, it is possible to provide a technology capable of reorganizing a manufacturing process according to the product specifications of grease.

Brief Description of the Drawings

[0010]

Figure 1

Modes for Carrying Out the Invention

[0011] [1. Grease Manufacturing System] A grease manufacturing system according to one aspect of the present invention includes a plurality of equipment units for grease manufacturing. Here, in this specification, the "equipment unit" means an aggregate of a plurality of devices and parts configured to have a predetermined function as one aggregate.

[0012] In the grease manufacturing system according to one aspect of the present invention, each equipment unit is connected and coordinated to manufacture grease. According to the above configuration, since the equipment unit can be replaced as needed, the manufacturing process can be recombined according to the product specifications of the grease.

[0013] Further, in the grease manufacturing system according to one aspect of the present invention, at least a part of the equipment unit is portable. Here, in this specification, "portable" means that the installation position of the equipment unit can be moved. The method of moving the equipment unit is not particularly limited. For example, the equipment unit may be lifted from the floor by a transport mechanism (such as a forklift) separate from the equipment unit and moved, or it may be moved using moving means such as casters provided on the bottom surface of the equipment unit.

[0014] According to the above configuration, since at least a part of the equipment unit is portable, the installation location of the equipment unit can be freely selected, and the replacement, movement, and connection with other equipment units of the equipment unit can be performed freely and easily.

[0015] In addition, since at least a part of the equipment unit is portable, the following effects are further achieved.

[0016] First, the movement of the equipment unit is easy. Since the movement in units within the factory or between factories is facilitated, it is possible to flexibly respond to manufacturing in a special environment such as a clean room or manufacturing using dedicated equipment.

[0017] In addition, since the distance between the equipment units can be minimized by moving the equipment units, the length of the piping connecting the equipment units can be set to the minimum necessary length. As a result, it is possible to reduce product loss in the piping part and reduce the cleaning oil for cleaning the piping, resulting in a cost reduction effect.

[0018] Furthermore, the number of parts such as piping can be reduced. This can reduce the cleaning man-hours of the grease manufacturing system, leading to a reduction in cleaning oil. Also, since cleaning becomes easier, contamination is less likely to occur.

[0019] Next, it is easy to add equipment units. By adding equipment units, the processing capacity can be easily enhanced. As a result, a low plant cost can be realized.

[0020] Next, it can easily cope with multi-product production. By using dedicated equipment units for each product and freely recombining the equipment units that make up the grease manufacturing system according to the product specifications of the grease, it is possible to flexibly respond to multi-product production. Also, the loss of base grease and the loss of time can be reduced. Examples of the time that can be reduced include manufacturing time, cleaning time, heating time, cooling time, etc. In this specification, "base grease" refers to a mixture of base oil and thickener and does not contain additives.

[0021] The specific type of grease produced by the grease manufacturing system according to one aspect of the present invention is not particularly limited. The grease manufacturing system according to one aspect of the present invention can be applied to the manufacture of any grease. Examples of the grease produced by the grease manufacturing system according to one aspect of the present invention include urea grease, soap-based thickener grease such as lithium and calcium, etc. Also, greases obtained by mixing several different types of these greases can be mentioned.

[0022] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In this embodiment, an aspect in which the grease manufacturing system according to an embodiment of the present invention includes the following equipment units (1) to (11) as a plurality of equipment units will be described as an example: (1) A base grease raw material solution preparation unit for preparing a raw material solution used for manufacturing a base grease containing a base oil and a thickener; (2) A base grease raw material storage unit for storing the raw material solution prepared by the base grease raw material solution preparation unit; (3) A base grease reaction unit for reacting the raw material solution to produce base grease; (4) A base grease storage unit for storing the base grease; (5) A mixing unit for mixing the base grease, an additive, and a diluent oil to produce a grease composition; (6) An additive unit for storing an additive to be added to the base grease; (7) A diluent oil unit for storing a diluent oil to be added to the base grease; (8) A milling unit for homogenizing the base grease or the grease composition; (9) A product storage unit for storing the homogenized base grease or the grease composition; (10) A filling unit for filling the base grease or the grease composition from the product storage unit into a container; (11) A heat exchanger unit for heat-treating and cooling the base grease.

[0023] By the grease manufacturing system according to the present embodiment including the equipment units (1) to (11), it is possible to manufacture, as products, heat-treated base grease and a grease composition containing the base grease.

[0024] However, the present invention is not limited thereto, and by appropriately recombining the equipment units included in the grease manufacturing system, it is also possible to obtain a manufacturing system for manufacturing another type of base grease or a grease composition containing the base grease as a product. For example, when heat treatment is not performed on the base grease, the heat exchanger unit can be omitted from the equipment units included in the grease manufacturing system.

[0025] (Grease Manufacturing System 100) An overview of a grease production system 100 according to this embodiment will be described with reference to Fig. 1. Fig. 1 is a diagram schematically illustrating the configuration of the grease production system 100 according to this embodiment. As shown in Fig. 1, the grease production system 100 includes a plurality of equipment units 1 to 11 for producing grease, a transport mechanism 30, and an automated multi-story warehouse 40. The transport mechanism 30 is a mechanism for transporting the equipment units 1 to 11 to predetermined positions on the production line of the grease production system 100. The automated multi-story warehouse 40 is a warehouse for storing equipment units 12 that are not used in the production process until they are to be used.

[0026] (multiple equipment units) The grease production system 100 of this embodiment includes multiple equipment units for producing grease, including a base grease raw material solution preparation unit 1, a base grease raw material storage unit 2, a base grease reaction unit 3, a base grease storage unit 4, a mixing unit 5, an additive unit 6, a dilution oil unit 7, a milling unit 8, a product storage unit 9, a filling unit 10, and a heat exchanger unit 11.

[0027] (Base grease raw material solution preparation unit 1) The base grease raw material solution preparation unit 1 is an equipment unit having the function of preparing a raw material solution used to manufacture a base grease. The base grease raw material solution preparation unit 1 includes a tank 13 that contains raw materials for preparing the raw material solution, and an agitator 14. By including the agitator 14, the raw material solution can be dissolved or mixed, or both dissolved and mixed.

[0028] The configuration of the base grease raw material solution preparation unit 1 is not limited to the above configuration and can be modified as appropriate as long as the base grease raw material solution preparation unit can perform its intended function. Furthermore, the base grease raw material solution preparation unit 1 may include components or devices other than those described above. Examples of such components or devices include heating and cooling devices, generated gas recovery devices, and pump devices.

[0029] The grease production system 100 includes one base grease stock solution preparation unit 1. In a grease production system according to one embodiment of the present invention, the number of base grease stock solution preparation units 1 can be adjusted as needed, and one or more base grease stock solution preparation units 1 can be provided. For example, when multiple types of base grease stock solution are prepared individually, it is preferable to provide multiple base grease stock solution preparation units 1 corresponding to the number of types of base grease stock solutions. It is also preferable to prepare a dedicated equipment unit as the base grease stock solution preparation unit 1 for each type of grease to be produced (i.e., for each product).

[0030] As an example, a case where urea grease is produced using the grease production system 100 according to this embodiment will be described. In producing urea grease, an isocyanate solution, a first amine solution (aliphatic amine), and a second amine solution (cyclic or aromatic amine) are mixed in any proportion to produce a base grease raw material solution. In this case, the grease production system 100 can be configured to include at least three base grease raw material solution preparation units 1. This allows the isocyanate solution, the first amine solution, and the second amine solution to be individually prepared in their own dedicated base grease raw material solution preparation units 1. Furthermore, since the physical properties of the raw materials vary, and the time required for dissolution and volatility are expected to differ, different temperature adjustments and dissolution time adjustments may be required. In this case, it is preferable to have multiple units.

[0031] (Base grease raw material storage units 2a, 2b) The base grease raw material storage units 2a and 2b are equipment units having the function of storing the raw material solution prepared in the base grease raw material solution preparation unit 1. Each of the base grease raw material storage units 2a and 2b is a tank unit equipped with a temperature adjustment jacket, and includes a tank 13 for storing the prepared raw material solution and a temperature adjustment jacket (not shown). As the tank 13, a vertical storage tank with a simple structure, a floating roof type storage tank, etc. can be used. In the following description, the two base grease raw material storage units 2a and 2b included in the grease manufacturing system 100 may be simply referred to as the base grease raw material storage unit 2 without distinction.

[0032] The configuration of the base grease raw material storage unit 2 is not limited to the above-described configuration, and can be appropriately changed within the range in which the intended function can be exhibited as the base grease raw material storage unit. Further, it may be provided with components or equipment other than the above-described components or equipment. Examples of such components or equipment include heating and cooling equipment, measuring instruments, generated gas recovery devices, and pump devices. Examples of the pump device include a vane pump, a screw pump, a gear pump, and a mono type. Further, the base grease raw material storage unit 2 may be provided with a double motion type stirrer for high viscosity stirring.

[0033] The grease manufacturing system 100 includes two base grease raw material storage units 2a and 2b. In the grease manufacturing system according to one aspect of the present invention, the number of the base grease raw material storage units 2 can be appropriately adjusted as needed, and one or more can be provided. For example, when preparing a plurality of types of base grease raw material solutions separately in the base grease raw material solution preparation unit 1, it is preferable to provide a plurality of base grease raw material storage units 2 corresponding to the number of types of the prepared base grease raw material solutions so that the prepared base grease raw material solutions can be stored separately. As an example, when manufacturing urea grease by the grease manufacturing system 100 according to the present embodiment, the base grease raw material storage unit 2 can be configured to include at least three so that three types of base grease raw material solutions, namely, an isocyanate solution, a first amine solution (aliphatic amine), and a second amine solution (cyclic or aromatic amine), can be stored separately.

[0034] (Base grease reaction unit 3) The base grease reaction unit 3 is a device unit having a function of reacting the raw material solution to generate base grease. The base grease reaction unit 3 is provided on the downstream side of the base grease raw material storage unit 2 in the manufacturing line of the grease manufacturing system 100. Here, in this specification, based on the direction in which the fluid flows in the grease manufacturing system 100, the downstream side of the flow is referred to as "downstream" of the manufacturing line, and the upstream side of the flow is referred to as "upstream" of the manufacturing line.

[0035] The base grease reaction unit 3 includes a base grease manufacturing device 16 that mixes a plurality of raw materials at high speed rotation to generate base grease. The base grease manufacturing device 16 is not particularly limited, and examples include conventionally known base grease manufacturing devices used for the purpose of applying a high shearing force to the base grease raw materials to generate base grease. For example, the grease manufacturing device disclosed in JP-A-2017-115109 can be mentioned.

[0036] The base grease reaction unit 3 is also equipped with a flow rate adjustment mechanism 15 that adjusts the flow rate of the raw material solution introduced into the base grease reaction unit 3. An example of the flow rate adjustment mechanism 15 is a mechanism that adjusts the flow rate of a pump in response to a signal from an ultrasonic flow meter. The base grease reaction unit 3 may also be equipped with an ultrasonic flow meter that measures the flow rate of the raw material solution introduced into the base grease reaction unit 3.

[0037] The configuration of the base grease reaction unit 3 is not limited to the above configuration and can be appropriately changed as long as the base grease reaction unit can perform its intended function. Furthermore, the base grease reaction unit 3 may be equipped with components or devices other than those described above. Examples of such components or devices include heating and cooling devices.

[0038] (Base grease storage unit 4) The base grease storage unit 4 is an equipment unit having the function of storing the base grease. The base grease storage unit 4 is provided downstream of the base grease reaction unit 3 in the production line of the grease production system 100.

[0039] The base grease storage unit 4 can include a tank 17 having a floating roof tank structure and an agitator 18. By including the agitator 18, the base grease in the tank 17 can be agitated. By agitating the base grease with the agitator 18, the base grease is softened by shear, making it easier to discharge the base grease from the tank 17 and reducing loss of production time.

[0040] The configuration of the base grease storage unit 4 is not limited to the above configuration and can be modified as appropriate as long as the base grease storage unit can perform its intended function. Furthermore, the base grease storage unit 4 may include components or devices other than those described above. Examples of such components or devices include a heating device. Heating the base grease using a heating device softens the base grease, facilitating and stabilizing the discharge of the base grease from the tank 17, ultimately reducing lost production time.

[0041] In a grease production system according to one embodiment of the present invention, the number of base grease storage units 4 can be adjusted as needed, and one or more can be provided. For example, a plurality of base grease storage units 4 can be provided in accordance with the number of types of base grease. As an example, when urea grease is produced using the grease production system 100 according to this embodiment, multiple types of base greases can be produced by blending any ratio from 100% first amine solution (aliphatic amine) to 100% second amine solution (cyclic or aromatic amine). In such a case, a configuration can be provided in which a plurality of base grease storage units 4 is provided in accordance with the number of types of base grease so that the multiple types of base grease can be stored individually.

[0042] (Mixed Unit 5) The mixing unit 5 is an equipment unit having the function of mixing a base grease, additives, and diluent oil to produce a grease composition. The mixing unit 5 is provided downstream of the base grease storage unit 4 in the production line of the grease production system 100. The mixing unit 5 may be a portable equipment unit or a fixed type.

[0043] The mixing unit 5 has an agitation tank equipped with a double-motion agitator (not shown). By providing the agitation tank with a double-motion agitator (not shown), the base grease, additives, and diluent oil can be mixed together.

[0044] The configuration of the mixing unit 5 is not limited to the above-described configuration, and can be appropriately changed within the range in which the intended function can be exhibited as the mixing unit. Further, it may be provided with components or devices other than the components or devices described above. Examples of such components or devices include a heating and cooling device, a pump device, and the like.

[0045] (Additive unit 6) The additive unit 6 is a device unit having a function of storing an additive to be added to the base grease. The additive unit 6 is provided upstream of the mixing unit 5 in the production line of the grease production system 100. The additive unit 6 is a portable device unit.

[0046] The additive unit 6 includes a tank 13 for storing the additive and a stirrer 14. By providing the stirrer 14, the additive can be mixed. The configuration of the additive unit 6 is not limited to the above-described configuration, and can be appropriately changed within the range in which the intended function can be exhibited as the additive unit. Further, it may be provided with components or devices other than the components or devices described above. Examples of such components or devices include a heating device and the like. For example, when the additive has a high viscosity, the production time can be shortened by using a heating device from the viewpoints of dissolution and mixability.

[0047] The additive unit 6 preferably has the same configuration as the base grease raw material solution preparation unit 1. By preparing a plurality of equipment units having the same configuration, they can be used both as the additive unit 6 and as the base grease raw material solution preparation unit 1. As a result, there is no need to prepare multiple types of equipment units with different configurations, such as an equipment unit for the additive unit 6 and an equipment unit for the base grease raw material solution preparation unit 1. Thus, it is not necessary to prepare more types of equipment units than necessary, leading to a reduction in the number of types of parts. Here, "having the same configuration" means that two or more equipment units are composed of the same types of parts and devices. For example, it means that the base grease raw material solution preparation unit 1 and the additive unit 6 are composed of the same types of parts and devices. It is preferable to prepare a dedicated equipment unit for each type of grease to be manufactured (i.e., for each product) as the additive unit 6.

[0048] (Diluent oil unit 7) The diluent oil unit 7 is an equipment unit having a function of storing diluent oil to be added to the base grease. The diluent oil unit 7 is provided upstream of the mixing unit 5 in the production line of the grease production system 100. The diluent oil unit 7 is a portable equipment unit.

[0049] The diluent oil unit 7 includes a tank 13 for storing diluent oil and one stirrer 14. By providing the stirrer 14, the diluent oil can be mixed.

[0050] The configuration of the diluent oil unit 7 is not limited to the above-described configuration and can be appropriately changed within the range where the intended function as a diluent oil unit can be exhibited. Also, it may be provided with parts or devices other than the above-described parts or devices.

[0051] (Milling unit 8) The milling unit 8 is an equipment unit that has the function of homogenizing the base grease or the grease composition. The milling unit 8 is provided downstream of the mixing unit 5 in the production line of the grease production system 100. The milling unit 8 is a portable equipment unit.

[0052] The milling unit 8 is individually equipped with devices such as a roll mill, colloid mill, and homogenizer, which enable the base grease or grease composition to be homogenized. These devices are not particularly limited, and examples include conventionally known mills, homogenizers, and the like, which are used for the purpose of homogenizing the base grease or grease composition.

[0053] The configuration of the milling unit 8 is not limited to the above configuration and can be modified as appropriate as long as the milling unit can perform its intended function. Furthermore, the milling unit 8 may include components or devices other than those described above. Examples of such components or devices include a pump device.

[0054] (Product Storage Unit 9) The product storage unit 9 is an equipment unit that has the function of storing the homogenized base grease or grease composition. The product storage unit 9 is provided downstream of the milling unit 8 in the production line of the grease production system 100. The product storage unit 9 is a portable equipment unit.

[0055] The product storage unit 9 includes a tank 17 having a floating roof tank structure and an agitator 18. The provision of the agitator 18 makes it possible to agitate the base grease or grease composition in the tank 17. By agitating the base grease or grease composition with the agitator 18, the base grease or grease composition is softened by shear, making it easier to discharge the base grease or grease composition from the tank 17 and reducing loss of production time.

[0056] The configuration of the product storage unit 9 is not limited to the above-described configuration, and can be appropriately changed within the range in which the intended function as the product storage unit can be exhibited. Further, it may be provided with components or devices other than the components or devices described above. Examples of such components or devices include a heating device and a pump device.

[0057] (Filling Unit 10) The filling unit 10 is a device unit that has a function of filling a container C with base grease or a grease composition from the product storage unit 9. The filling unit 10 includes a supply pump (not shown), a filter device, and a filling machine. The filling unit 10 is a portable device unit.

[0058] The configuration of the filling unit 10 is not limited to the above-described configuration, and can be appropriately changed within the range in which the intended function as the filling unit can be exhibited. Further, it may be provided with components or devices other than the components or devices described above.

[0059] (Heat Exchanger Unit 11) The heat exchanger unit 11 is a device unit that has a function of heating and cooling the base grease. In the grease manufacturing system according to one aspect of the present invention, the heat exchanger unit 11 is a device unit that is provided as necessary. When the grease manufacturing system according to one aspect of the present invention includes the heat exchanger unit 11, as shown in FIG. 1, the heat exchanger unit 11 is preferably disposed between the base grease reaction unit 3 and the base grease storage unit 4 in the manufacturing line of the grease manufacturing system 100.

[0060] The heat exchanger unit 11 includes a special heat exchanger 19 that cools the base grease after heating it. By providing the special heat exchanger 19, the base grease can be heated and cooled. In addition to the special heat exchanger 19, a conventionally known heat exchanger used for the purpose of heating and cooling the base grease can also be used.

[0061] The configuration of the heat exchanger unit 11 is not limited to the above-described configuration, and can be appropriately changed within the range in which the intended function as a heat exchanger unit can be exhibited. Further, components or devices other than the above-described components or devices may be provided. Examples of such components or devices include a heat medium supply device and a pump device.

[0062] (Direction of introduction and discharge of fluid to each equipment unit) The black arrows in Fig. 1 represent the direction of introduction and discharge of fluid to the equipment unit. The introduction and discharge of fluid to the equipment unit can be performed through piping or the like. For example, in the grease manufacturing system 100, circulation piping (not shown) is installed inside the base grease raw material storage unit 2, inside the mixing unit 5, between the mixing unit 5 and the milling unit 8, and between the mixing unit 5 and the heat exchanger unit 11, respectively, enabling the circulation process of fluid between the equipment units.

[0063] In the grease manufacturing system 100 according to the present embodiment, the introduction of the raw material solution into the base grease reaction unit 3 can be performed from at least one of the base grease raw material solution preparation unit 1 and the base grease raw material storage unit 2. From the viewpoints of flow rate stabilization of the pump for supplying the raw material solution to the base grease reaction unit 3 and continuous operation, rather than directly introducing the raw material solution from the base grease raw material solution preparation unit 1 into the base grease reaction unit 3, it is preferable to once store the base grease raw material solution from the base grease raw material solution preparation unit 1 in the base grease raw material storage unit 2 and then introduce the raw material solution from the base grease raw material storage unit 2 into the base grease reaction unit 3.

[0064] In the grease manufacturing system 100 according to the present embodiment shown in FIG. 1, an example is shown in which the mixing unit 5, the additive unit 6, the diluent oil unit 7, the milling unit 8, the product storage unit 9, and the filling unit 10 are portable equipment units. However, the present invention is not limited to this. The grease manufacturing system according to one aspect of the present invention can make at least a part of the equipment units portable, and the types of equipment units to be made portable can be appropriately selected according to need. For example, the mixing unit, the additive unit, and the diluent oil unit may be portable; the mixing unit, the additive unit, the diluent oil unit, and the milling unit may be portable; the mixing unit, the additive unit, the diluent oil unit, the milling unit, and the product storage unit may be portable.

[0065] By making at least the mixing unit, the additive unit, and the diluent oil unit among the plurality of equipment units included in the grease manufacturing system according to one aspect of the present invention portable, the piping distance can be shortened, and consequently the pressure loss can be reduced, enabling steady operation in a short time. Further, since the piping distance is shortened, cleaning becomes easier, resulting in a reduction in the contamination risk. Furthermore, since the cost of replacing the piping is reduced, the piping can be easily replaced, and the contamination risk is reduced.

[0066] A specific example will be given to explain the effect of the above-mentioned easier cleaning. For example, when flowing a product using a piping of a general length of about 5 m to 10 m, when cleaning this piping, it may be necessary to flow a grease for co-washing. In that case, even if a sufficient amount of the grease for co-washing is introduced, there is a possibility that the grease remaining inside the piping cannot be completely flushed out. Also, when the piping is long, in addition to flowing with the grease for co-washing, it may be necessary to clean using special tools, increasing the cost of cleaning.

[0067] On the other hand, if the piping length can be shortened to a few tens of centimeters, the possibility of the grease not being able to flow completely can be reduced, thereby reducing the risk of contamination.In addition, if the piping is short, there is no need to use special tools for cleaning, and the piping is easy to replace, so the costs of cleaning and replacing the piping can be reduced.

[0068] Furthermore, among the multiple equipment units included in the grease production system according to one embodiment of the present invention, at least the mixing unit, additive unit, dilution oil unit, and milling unit are portable, thereby shortening the piping distance connecting these equipment units, thereby achieving the above-mentioned advantages of shorter piping distances.

[0069] Furthermore, among the multiple equipment units included in the grease production system according to one embodiment of the present invention, at least the mixing unit, additive unit, diluent oil unit, milling unit, and product storage unit are portable, thereby shortening the piping distances connecting these equipment units, thereby achieving the aforementioned benefits of shorter piping distances.

[0070] Furthermore, by making at least the mixing unit, additive unit, dilution oil unit, milling unit, product storage unit, and filling unit portable among the multiple equipment units included in the grease production system according to one aspect of the invention, as in the grease production system 100 according to this embodiment, the piping distances connecting these equipment units can be shortened, thereby achieving the aforementioned advantages of shorter piping distances.

[0071] (Transport mechanism 30) The transport mechanism 30 is a mechanism for transporting a portable equipment unit to a predetermined position in the grease production system 100. The transport mechanism 30 includes a stacker crane 31 and a transfer conveyor 32.

[0072] By providing the transfer mechanism 30, as shown in FIG. 1, the equipment unit 12 stored in the three-dimensional automatic warehouse 40 can be taken out by the stacker crane 31 and conveyed to a predetermined position in the grease manufacturing system 100 by the transfer conveyor 32. Further, the distance between the equipment units in the grease manufacturing system 100 can be adjusted by the transfer conveyor 32.

[0073] Also, the equipment unit can be moved to a location according to the grease manufacturing process by the transfer conveyor 32. For example, the product storage unit 9 for storing the homogenized base grease or grease composition is conveyed by the transfer conveyor 32 to the position where the filling unit 10 is installed during the filling process of filling the base grease or grease composition into the container C. The white arrows in FIG. 1 represent the movement of the equipment unit on the transfer conveyor 32.

[0074] In the grease manufacturing system 100 shown in FIG. 1, as an example of the transfer mechanism 30, an example is shown in which the transfer mechanism 30 includes the stacker crane 31 and the transfer conveyor 32, but the transfer mechanism 30 is not limited thereto. Examples of the transfer mechanism 30 include conventionally known transfer devices used for the purpose of transferring an object. For example, the equipment unit may be transferred by a forklift or the like.

[0075] (Three-dimensional automatic warehouse 40) The three-dimensional automatic warehouse 40 stores the equipment units 12 not used in the manufacturing process. Each equipment unit after use may be conveyed to the three-dimensional automatic warehouse 40 and stored as it is until it is used in the manufacturing process next. Each equipment unit after use that has been conveyed to the three-dimensional automatic warehouse 40 may be periodically subjected to a cleaning process such as a tank for the purpose of maintaining the equipment unit. The equipment unit after cleaning is stored in the three-dimensional automatic warehouse 40 until it is used next.

[0076] [2. Grease manufacturing method] Hereinafter, the grease manufacturing method according to an embodiment of the present invention will be described in detail with reference to FIG. 1.

[0077] In this embodiment, an example of carrying out a grease production method including the following steps (a) to (f) using the above-described grease production system 100 will be described: (a) a base grease raw material solution preparation step of preparing a raw material solution to be used for producing a base grease containing a base oil and a thickener; (b) a base grease reaction step in which the raw material solution is reacted to produce a base grease; (c) a mixing step of mixing the base grease, additives, and diluent oil to produce a grease composition; (d) a milling step in which the base grease or the grease composition is homogenized; (e) a filling step of filling the base grease or the grease composition after the milling step into a container; (f) a heat treatment step in which the base grease is heated and cooled.

[0078] The grease manufacturing method according to this embodiment includes steps (a) to (f), and thus a heat-treated base grease and a grease composition containing the base grease can be manufactured as products. However, the present invention is not limited to this. For example, if the base grease is not heat-treated, step (f) can be omitted.

[0079] (Step (a): Base grease raw material solution preparation step) First, in step (a), a raw material solution used to produce a base grease containing a base oil and a thickener is prepared in a base grease raw material solution preparation unit 1. The base grease raw material solution prepared in step (a) may be one type or multiple types. When multiple types of base grease raw material solutions are prepared individually, it is preferable to provide multiple base grease raw material solution preparation units 1 corresponding to the number of types of raw material solutions.

[0080] The type of the base grease raw material solution prepared in step (a) is not particularly limited. The type of the base grease raw material solution can be appropriately selected according to the type of the grease to be produced. Further, the processing conditions in the base grease raw material solution preparation unit 1 can be appropriately selected according to the base grease raw material solution to be prepared.

[0081] The raw material solution prepared in the base grease raw material solution preparation unit 1 is stored in a separate base grease raw material storage unit 2 for each type of the raw material solution.

[0082] (Step (b): Base grease reaction step) In step (b), in the base grease reaction unit 3, the base grease raw material solution is reacted to generate base grease.

[0083] In step (b), the base grease reaction unit 3 introduces a plurality of the base grease raw material solutions from either one of one or more base grease raw material solution preparation units 1 and one or more base grease raw material storage units 2, or from both one or more base grease raw material solution preparation units 1 and one or more base grease raw material storage units 2, and reacts them. In step (b), from the viewpoint of completing the reaction without waste, it is preferable to react the base grease raw material solution while adjusting the flow rate of the base grease raw material solution introduced into the base grease reaction unit 3 by the flow rate adjustment mechanism 15.

[0084] The reaction conditions in the base grease reaction unit 3 can be appropriately selected according to the base grease raw material solution used in the reaction.

[0085] The base grease generated in the base grease reaction unit 3 exits the base grease reaction unit 3 and is introduced into the heat exchanger unit 11 for heat treatment.

[0086] (Step (f): Heat treatment step) When performing step (f), step (f) is carried out between step (b) and step (c). In step (f), in the heat exchanger unit 11, the base grease is subjected to heat treatment and cooling treatment. By subjecting the base grease to heat treatment, the reaction can be completed and the crystal form of the thickener can be stabilized. Also, by subjecting the base grease to cooling treatment, the effects of preventing side reactions, preventing thermal degradation, and preventing evaporation of the raw materials can be achieved.

[0087] In step (f), the base grease is introduced from the base grease reaction unit 3 to the heat exchanger unit 11, or from the base grease storage unit 4 to the heat exchanger unit 11.

[0088] The heat treatment conditions in the heat exchanger unit 11 can be appropriately selected according to the base grease raw material solution used in the reaction.

[0089] The base grease heat-treated in the heat exchanger unit 11 is stored in the base grease storage unit 4. A part of the base grease stored in the base grease storage unit 4 is introduced into the mixing unit 5 to produce a grease composition. Also, another part of the base grease stored in the base grease storage unit 4 exits the base grease storage unit 4 and is introduced into the milling unit 8 to undergo a homogenization process for producing a base grease product.

[0090] (Step (c): Mixing Step) In step (c), in the mixing unit 5, the base grease, the additive, and the diluent oil are mixed to produce a grease composition.

[0091] In step (c), the mixing unit 5 introduces base grease, an additive, and diluent oil from the base grease storage unit 4, the additive unit 6, and the diluent oil unit 7, respectively, and mixes them to produce a grease composition. As the additive unit 6, a device unit having the same configuration as the base grease raw material solution preparation unit 1 used in the step (a) can be used. Thereby, since device units having the same configuration can be used in a plurality of different manufacturing steps, it is not necessary to prepare more types of device units than necessary, leading to a reduction in the number of types of parts.

[0092] The types and amounts of the additive and diluent oil added to the base grease can be appropriately selected according to the grease composition to be manufactured. As the additive added to the base grease, conventionally known additives used in the production of grease can be used. Also, as the diluent oil added to the base grease, conventionally known diluent oils used in the production of grease can be used.

[0093] The mixing conditions in the mixing unit 5 can be appropriately selected according to the base grease, additive, and diluent oil used for mixing, and also according to the specifications of the grease composition product to be manufactured.

[0094] The grease composition produced in the mixing unit 5 exits the mixing unit 5 and is introduced into the milling unit 8 in order to undergo a homogenization process.

[0095] (Step (d): Milling step) In step (d), in the milling unit 8, the base grease or the grease composition is homogenized. By homogenizing the base grease or the grease composition, the dispersion state of the thickener can be made uniform and the quality can be stabilized.

[0096] In step (d), the milling unit 8 introduces base grease from the base grease storage unit 4 and homogenizes it. Alternatively, the milling unit 8 introduces the grease composition from the mixing unit 5 and homogenizes it.

[0097] The conditions for the homogenization treatment in the milling unit 8 can be selected according to the base grease or grease composition to be processed, and also according to the specifications of the base grease product or grease composition product to be manufactured.

[0098] The base grease or grease composition homogenized in the milling unit 8 is respectively stored in the product storage unit 9 or supplied to the filling unit 10.

[0099] (Step (e): Filling step) In step (e), in the filling unit 10, the base grease or grease composition after the milling step is filled into the container C. The filling unit 10 fills the homogenized base grease or grease composition stored in the product storage unit 9 into the container C.

[0100] According to the grease manufacturing method as described above, it is possible to easily cope with multi-variety production.

[0101] [Summary] The grease manufacturing system according to Aspect 1 of the present invention includes a plurality of equipment units for manufacturing grease, and at least a part of the equipment units is portable. Thereby, it is possible to provide a technology capable of recombining the manufacturing process according to the product specifications of grease.

[0102] The grease manufacturing system according to Aspect 2 of the present invention includes, in the above Aspect 1, the following equipment units (1) to (10) as the plurality of equipment units: (1) A base grease raw material solution preparation unit for preparing a raw material solution used for manufacturing a base grease containing base oil and thickener; (2) A base grease raw material storage unit for storing the raw material solution prepared by the base grease raw material solution preparation unit; (3) A base grease reaction unit for reacting the raw material solution to produce base grease; (4) A base grease storage unit for storing the base grease; (5) A mixing unit for mixing the base grease, an additive, and a diluent oil to produce a grease composition; (6) An additive unit for storing the additive to be added to the base grease; (7) A diluent oil unit for storing the diluent oil to be added to the base grease; (8) A milling unit for homogenizing the base grease or the grease composition; (9) A product storage unit for storing the homogenized base grease or the grease composition; (10) A filling unit for filling the base grease or the grease composition from the product storage unit into a container. Optionally, it is equipped with the following equipment unit (11): (11) A heat exchanger unit for heat-treating and cooling the base grease; The heat exchanger unit may be arranged between the base grease reaction unit and the base grease storage unit.

[0103] Thereby, it can easily cope with multi-variety production.

[0104] The grease manufacturing system according to Embodiment 3 of the present invention may include a plurality of the base grease raw material solution preparation units and the base grease raw material storage units respectively in the above Embodiment 2. Thereby, the grease manufacturing system according to one aspect of the present invention can also be applied to a manufacturing process for producing base grease by reacting a plurality of types of base grease raw material solutions.

[0105] A grease production system according to a fourth aspect of the present invention is the same as that of the second or third aspect, wherein the base grease reaction unit introduces the raw material solution from at least one of the base grease raw material solution preparation unit and the base grease raw material storage unit, and the base grease reaction unit may be equipped with a flow rate adjustment mechanism that adjusts the flow rate of the raw material solution introduced into the base grease reaction unit. This allows the piping distance connecting these equipment units to be shortened. As a result, the shorter piping distance reduces the costs associated with cleaning and replacing piping, and the risk of contamination can be reduced.

[0106] A grease production system according to aspect 5 of the present invention is any one of aspects 2 to 4 above, wherein the base grease storage unit introduces the base grease from the base grease reaction unit, or, if the grease production system is equipped with a heat exchanger unit, the base grease storage unit may introduce the heat-treated base grease from the heat exchanger unit.

[0107] A grease production system according to a sixth aspect of the present invention is any one of the second to fifth aspects, and preferably the additive unit, the dilution oil unit, and the mixing unit are portable. This allows the piping distance connecting these equipment units to be shortened. As a result, the short piping distance reduces the costs associated with cleaning and replacing the piping, and the risk of contamination can be reduced.

[0108] A grease production system according to a seventh aspect of the present invention is any one of the above-mentioned second to sixth aspects, and preferably the milling unit is portable. This allows the piping distance connecting these equipment units to be shortened. As a result, the short piping distance reduces the costs for cleaning and replacing the piping, and the risk of contamination can be reduced.

[0109] In the grease manufacturing system according to Aspect 8 of the present invention, in any one of the above Aspects 2 to 7, it is preferable that the product storage unit is portable. Thereby, the piping distance for connecting between these equipment units can be shortened. As a result, it is possible to enjoy the advantages of cost reduction for cleaning and replacement of the piping due to the short piping distance, and reduction of the contamination risk.

[0110] In the grease manufacturing system according to Aspect 9 of the present invention, in any one of the above Aspects 2 to 8, it is preferable that the filling unit is portable. Thereby, the piping distance for connecting between these equipment units can be shortened. As a result, it is possible to enjoy the advantages of cost reduction for cleaning and replacement of the piping due to the short piping distance, and reduction of the contamination risk.

[0111] In the grease manufacturing system according to Aspect 10 of the present invention, in any one of the above Aspects 2 to 9, it is preferable that the additive unit has the same configuration as the base grease raw material solution preparation unit. Thereby, as the base grease raw material solution preparation unit and the additive unit, equipment units having the same configuration can be used, so it is not necessary to prepare more types of equipment units than necessary, leading to a reduction in the number of types of parts.

[0112] The method for manufacturing grease according to Aspect 11 of the present invention is a method for manufacturing grease by the grease manufacturing system described in any one of the above Aspects 1 to 10, including the following steps (a) to (e): (a) A base grease raw material solution preparation step of preparing a raw material solution used for manufacturing a base grease containing a base oil and a thickener; (b) A base grease reaction step of reacting the raw material solution to generate a base grease; (c) A mixing step of mixing the base grease, an additive, and a diluent oil to produce a grease composition; (d) A milling step of homogenizing the base grease or the grease composition; (e) A filling step of filling the base grease or the grease composition after the milling step into a container. Optionally, it includes the following step (f): (f) A heat treatment step of heat-treating and cooling the base grease. The heat treatment step is performed between the base grease reaction step and the mixing step.

[0113] Thereby, it can easily cope with multi-variety production.

[0114] In the method for manufacturing grease according to Embodiment 12 of the present invention, in the above Embodiment 11, it is preferable to perform the base grease raw material solution preparation step using a device unit having the same configuration as the device unit for storing the additive used in the mixing step.

[0115] Thereby, since device units having the same configuration can be used in a plurality of different manufacturing steps, it is not necessary to prepare more types of device units than necessary, leading to a reduction in the number of types of parts.

[0116] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope shown in the claims. Embodiments obtained by appropriately combining the technical means disclosed in each embodiment are also included in the technical scope of the present invention.

Explanation of Reference Numerals

[0117] 1 Base grease raw material solution preparation unit 2 Base grease raw material storage unit 3 Base grease reaction unit 4 Base grease storage unit 5 Mixing unit 6 Additive unit 7 Diluent oil unit 8 Milling unit 9 Product storage unit 10 Filling unit 11 Heat exchanger unit 15 Flow adjustment mechanism 100 Grease manufacturing system

Claims

1. A grease manufacturing system comprising a plurality of equipment units, at least a part of which is portable, for manufacturing grease.

2. The plurality of equipment units include the following equipment units (1) to (10): (1) A base grease raw material solution preparation unit for preparing a raw material solution used for manufacturing base grease containing base oil and thickener; (2) A base grease raw material storage unit for storing the raw material solution prepared by the base grease raw material solution preparation unit; (3) A base grease reaction unit for reacting the raw material solution to generate base grease; (4) A base grease storage unit for storing the base grease; (5) A mixing unit for mixing the base grease, an additive, and a diluent oil to manufacture a grease composition; (6) An additive unit for storing an additive to be added to the base grease; (7) A diluent oil unit for storing a diluent oil to be added to the base grease; (8) A milling unit for homogenizing the base grease or the grease composition; (9) A product storage unit for storing the homogenized base grease or the grease composition; (10) A filling unit for filling the base grease or the grease composition from the product storage unit into a container. Optionally, it further includes the following equipment unit (11): (11) A heat exchanger unit for heat-treating and cooling the base grease. The heat exchanger unit is arranged between the base grease reaction unit and the base grease storage unit. The grease manufacturing system according to Claim 1.

3. The grease manufacturing system according to Claim 2, comprising a plurality of the base grease raw material solution preparation units and a plurality of the base grease raw material storage units respectively.

4. The base grease reaction unit introduces the raw material solution from at least one of the base grease raw material solution preparation unit and the base grease raw material storage unit, and the base grease reaction unit is provided with a flow rate adjustment mechanism for adjusting the flow rate of the raw material solution introduced into the base grease reaction unit. The grease manufacturing system according to Claim 2 or 3.

5. The base grease storage unit introduces base grease from the base grease reaction unit, or ​ ​ ​ ​ When the grease manufacturing system includes the heat exchanger unit, the base grease storage unit introduces the base grease heat-treated by the heat exchanger unit. The grease manufacturing system according to any one of claims 2 to 4.

6. The grease manufacturing system according to any one of claims 2 to 5, wherein the additive unit, the diluent oil unit, and the mixing unit are portable.

7. The grease manufacturing system according to any one of claims 2 to 6, wherein the milling unit is portable.

8. The grease manufacturing system according to any one of claims 2 to 7, wherein the product storage unit is portable.

9. The grease manufacturing system according to any one of claims 2 to 8, wherein the filling unit is portable.

10. The grease manufacturing system according to any one of claims 2 to 9, wherein the additive unit has the same configuration as the base grease raw material solution preparation unit.

11. A method for manufacturing grease by the grease manufacturing system according to any one of claims 1 to 10, including the following steps (a) to (e): (a) A base grease raw material solution preparation step of preparing a raw material solution used for manufacturing a base grease containing a base oil and a thickener; (b) A base grease reaction step of reacting the raw material solution to generate a base grease; (c) A mixing step of mixing the base grease, an additive, and a diluent oil to manufacture a grease composition; (d) A milling step of homogenizing the base grease or the grease composition; (e) A filling step of filling the base grease or the grease composition after the milling step into a container, optionally including the following step (f): (f) A heat treatment step of heat-treating and cooling the base grease; The heat treatment step is performed between the base grease reaction step and the mixing step. Grease manufacturing method.

12. The grease manufacturing method according to claim 11, wherein the base grease raw material solution preparation step is performed using a device unit having the same configuration as the device unit for storing the additive used in the mixing step.

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