LoRaWAN-enabled single-point lubricator for remote maintenance

Industrial facilities in sectors such as mining, food processing, power generation, and heavy manufacturing rely on consistent lubrication to prevent premature wear and unplanned downtime. In this context, Lubrication Engineers introduced the Xport^® Star Vario Long Range lubrication system, an automatic single-point lubricator that combines electromechanical dosing with LoRaWAN^® wireless connectivity for remote monitoring and control.

Controlled lubricant delivery at the component level
The system is designed for single-point lubrication of components including rolling and plain bearings, linear guides, open gears, gear racks, chains, spindles, shaft seals, and electric motors. It uses a reusable electromechanical drive, a battery pack, and a replaceable lubrication cartridge available in 60, 120, 250, or 500 cc sizes.

The drive unit can generate up to 109 psi (7.5 bar), enabling lubricant delivery even where flow resistance is high due to long lines or tight lubrication points. Users can set discharge periods from one to 26 weeks or up to 12 months, depending on cartridge size and application needs. This controlled dosing helps reduce both under-lubrication, which accelerates wear, and over-lubrication, which can cause seal damage and energy losses.

Wireless supervision over long distances
Integrated LoRaWAN technology allows the lubricator to be monitored and configured remotely using the perma^® Connect app and a LoRa^® gateway. A single gateway can support up to 2,000 lubricators and receive data from up to eight devices simultaneously within a radius of up to 1.2 miles (2 km), depending on site layout and interference.

Communication uses standard radio protocols with 128-bit AES end-to-end encryption. Each unit checks for new commands at least once per hour and sends status updates whenever operating conditions change. Reported data includes operating status, timestamp, date, ambient temperature, and remaining fill level. This setup supports centralized maintenance planning and aligns with broader industrial IoT strategies used in the digital supply chain.

Designed for hazardous and hard-to-reach locations
By enabling remote configuration and monitoring, the system reduces the need for technicians to access elevated, confined, or otherwise hazardous areas for routine lubrication checks. Cartridge replacement can be carried out while equipment remains in operation, helping maintain production continuity.

A backlit LCD with push-button control and 360-degree visible LED indicators provide local status information and allow manual adjustments when needed. These features support both remote and on-site maintenance workflows.

Operating range and installation flexibility
The system is compatible with all Star LC cartridge sizes and can dispense grease up to NLGI 2. Cartridges other than the 500 cc version can also be filled with oil; oil-filled units are marked with a red plug and require an oil-retaining valve.

Operating temperature ranges from -4 to 140°F (-20 to 60°C) with alkaline batteries and from -40 to 140°F (-40 to 60°C) with lithium batteries. Protection ratings of IP65 and IP67 indicate resistance to dust ingress and water exposure, which is important in outdoor and washdown environments. The lubricator can also be mounted remotely up to 5 meters (5.5 yards) from the lubrication point, allowing installation where space or vibration limits direct mounting.

Together, automated dosing and long-range wireless connectivity provide a way to integrate lubrication tasks into centralized, data-driven maintenance systems, reducing manual inspection effort while improving asset reliability.

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