Condition-Based Lubrication: An Easy Way to Save Big

When it comes to machine reliability, one of the most critical yet often overlooked aspects is bearing maintenance. Improper bearing lubrication can lead to excessive wear, increased downtime, and significant expenses in bearing replacements. Enter condition-based greasing, an innovative approach that uses ultrasound technology to measure friction in bearings and detect the right time to grease and the right amount, resulting in substantial cost savings.

The Traditional Approach to Greasing Bearings

In the past, the conventional method for bearing maintenance was a time-based approach. Bearings were regularly greased at fixed intervals, regardless of their actual condition. While this method provided some level of protection, it was far from efficient.

One of the major drawbacks of scheduled greasing is over-lubrication. Excess grease can lead to increased friction, higher operating temperatures, and even premature bearing failure. Furthermore, the environmental impact of over-lubrication cannot be ignored, as it results in the unnecessary disposal of grease, which is harmful to both ecosystems and budgets.

The Power of Ultrasound Technology

Condition-based lubrication, on the other hand, relies on ultrasound technology to monitor the health of bearings in real-time. Ultrasound instruments are capable of detecting subtle changes in friction within bearings. These changes serve as early indicators of potential issues, allowing maintenance teams to take action precisely when it's needed, rather than adhering to a rigid schedule.

The process is straightforward:

1.Baseline Measurement: An initial baseline measurement becomes the reference point for future readings.

2. Regular Monitoring: Ultrasound instruments are regularly used to measure the friction levels of the bearing. Any significant deviation from the baseline indicates a potential problem. This may be facilitated by a tool like UE Systems’ Ultraprobe. However, many are shifting to remote continuous monitoring through sensor technology like UE Systems’ OnTrak system.

3. Targeted Greasing: When the ultrasound readings indicate increased friction, it's a sign that the bearing requires lubrication. Maintenance teams can then apply grease precisely where it's needed, eliminating over-lubrication and ensuring optimal bearing performance. Or, if the OnTrak is used, the bearing will be lubricated automatically with the correct amount through the system’s single-point lubricator.

Counting the Savings

The benefits of condition-based lubrication are not just theoretical; they translate into tangible cost savings for businesses. Here's how:

1. Reduced Grease Consumption: With condition-based lubrication, you only apply grease when necessary, eliminating wasteful over-lubrication. Furthermore, you are only greasing the exact amount needed to restore the bearing back to optimal condition. This can result in a significant reduction in grease consumption, leading to substantial cost savings.

2. Minimized Downtime: Unplanned bearing failures can lead to unexpected downtime, which is costly in terms of lost production and emergency repairs. According to a 2016 study, the average cost of downtime across all businesses was $260,000 per hour. That was a 60% increase from 2014. By detecting issues early and addressing them proactively, condition-based lubrication minimizes downtime and keeps operations running smoothly.

3. Extended Bearing Life: Proper lubrication based on actual conditions helps extend the life of bearings. This means fewer bearing replacements, which can be a substantial expense in terms of both parts and labor.

4. Environmental Benefits: Condition-based lubrication not only saves money but also contributes to environmental sustainability. Less grease wastage means fewer pollutants and less impact on the environment. In one meta-analysis, 88% of studies found that companies that adhered to social or environmental standards showed better operational performance, and 80% of studies showed a positive effect on stock price performance.

Conclusion

Condition-based lubrication, powered by ultrasound technology, is revolutionizing the way we maintain bearings in industrial settings. By moving away from rigid time-based schedules and adopting a proactive, data-driven approach, businesses can realize significant cost savings in terms of reduced grease consumption, minimized downtime, and extended bearing life.

In an era where efficiency and sustainability are paramount, condition-based lubrication is not just a smart choice; it's an essential one. It not only saves big in terms of dollars but also plays a crucial role in minimizing our industrial footprint on the planet. As industries continue to evolve, embracing innovative maintenance practices like condition-based lubrication will undoubtedly become the norm, ensuring a smoother, greener, and more cost-effective future.