Ultrasonic Lubrication: A Pragmatic Method for Determining the Correct Amount of Grease

Proper lubrication is essential for efficient and reliable machine operation.

Traditionally, maintenance schedules are based on operating hours, with lubricants applied at regular intervals. While logical, this approach does not take into account dynamic factors such as load variations, environmental conditions and temperature changes. To avoid over- or under-lubrication, which can lead to increased friction and wear, ultrasonic equipment offers a more precise solution. Using ultrasonic measurements, maintenance teams can accurately determine when and how much grease to apply, ensuring optimum machine performance.

One of the most advanced tools available for this purpose is the LUBExpert, a device specially designed to streamline lubrication processes through precise ultrasonic analysis.

The challenge of traditional lubrication methods

In industrial applications, lubrication operations are designed to minimize friction and efficiently remove heat and contaminants. Companies typically follow schedules that specify which components need to be lubricated and when. These schedules are often based on fixed intervals, such as weekly, monthly, or semi-annually. However, this static approach does not account for variations in operating conditions.

A more dynamic method involves lubrication based on operating hours, which helps avoid premature lubrication for machines that are used irregularly. Visual and auditory inspections are also common, but these methods do not take into account changing lubrication needs due to factors such as machine overload or temperature fluctuations. Such conditions can lead to under-lubrication, resulting in increased friction, energy consumption and noise levels, as well as reduced component life.

The ultrasonic solution

Ultrasonic devices offer a sophisticated method for determining the correct amount of lubricant. By detecting high-frequency vibrations caused by metal-to-metal contact in bearings, ultrasonic devices identify friction levels above 20,000 Hz, which are inaudible to the human ear. This technology is a subset of ultrasonic spectrum-based vibration analysis.

The LUBExpert stands out in this area. It is designed not only to detect these high-frequency sound waves, but also to convert them into actionable information. The device uses an advanced spectrum analysis program to transform ultrasonic signals into sound and visual formats, allowing maintenance personnel to accurately assess the lubrication needs of machines.

Practical applications of LUBExpert in ultrasonic lubrication

Reference measurements

To effectively implement ultrasonic lubrication, companies must first perform reference measurements on properly lubricated bearings. These reference values serve as benchmarks for future evaluations. The LUBExpert excels in capturing these reference values with high accuracy.

Regular monitoring

With LUBExpert, technicians can regularly monitor bearings to detect deviations from reference measurements. When the device detects amplitude increases above a certain threshold (usually around 8 dB), it signals the need for lubrication. This method allows maintenance actions to be scheduled at the precise moment they are needed, avoiding both over-lubrication and under-lubrication.

Optimized lubricant application

During lubrication, the LUBExpert accurately measures noise levels, guiding technicians to add grease until the optimum decibel value is reached. This feedback mechanism prevents over-lubrication, which can lead to increased friction and unnecessary grease usage. If noise levels increase due to excess grease, the LUBExpert alerts the technician to stop and clean the bearing.

The benefits of using LUBExpert

Accuracy and reliability

LUBExpert’s advanced technology provides accurate and reliable measurements, enabling proper lubrication. Its ability to isolate high-frequency sounds ensures that measurements are not contaminated by background noise, a common problem in industrial environments.

User-friendly interface

The LUBExpert has been designed to be easy to use and require minimal training. Its intuitive interface and clear displays make it accessible to maintenance teams, even those with busy schedules.

Real-time data and trend analysis

The LUBExpert supports real-time measurements and can store large volumes of data for trend analysis, including through the Ultranalysis Suite 3 data management software. This feature allows maintenance teams to track historical lubrication activities and make data-driven decisions, improving maintenance planning and efficiency.

Implementation of the solution

When integrating LUBExpert into lubrication practices, it is advisable to partner with SDT for comprehensive support and training. This helps ensure the technology is used effectively from the outset and maximizes its benefits.

Recording lubrication activities, including dates and grease quantities, is crucial. UAS3 software makes this task easy by allowing easy data entry and retrieval, ensuring accurate tracking and analysis. This practice helps determine the optimal amount of grease for each bearing, preventing premature or late lubrication.

By refining lubrication intervals based on ultrasonic measurements from the LUBExpert, companies can reduce labor hours and lubricant usage, resulting in cost savings. More frequent lubrication, when necessary, prevents unnecessary friction, extends component life and reduces energy consumption.

The LUBExpert represents a significant advancement in maintenance technology, delivering accurate and reliable measurements that traditional methods cannot match. By adopting the LUBExpert, companies can ensure that their machines are operating efficiently and reliably, reducing downtime and maintenance costs. As the technology continues to evolve, it promises even greater benefits for industrial maintenance, making it an essential tool for any maintenance department. With the LUBExpert, the future of lubrication maintenance is not only accurate but also exceptionally efficient.