The 3 Biggest Mistakes in Bearing Lubrication
Friction is ubiquitous in the environment in which we live. It is both a necessity for daily life and an indispensable element in industrial production. Without friction, it is difficult for us to walk, run, or even stand; and in the industrial field, friction is the key force driving automobiles , airplanes , and all kinds of machinery and equipment . However, friction is both friend and foe for factory machinery, especially in the link of lubrication , how to deal with friction is directly related to the service life and operation efficiency of machinery.
In a factory environment, rolling bearings are an essential component for the proper functioning of machinery, and their lubrication is key to ensuring long life and efficient bearing operation. Unfortunately, however, many bearings fail to reach their design life cycle due to improper lubrication. According to statistics, about 40% of the bearings due to poor lubrication and early failure. Behind this statistic lies an urgent need for a deep understanding and proper execution of lubrication tasks.
Lubrication of bearings mainly relies on grease, which can effectively reduce the level of friction and protect bearings from wear and damage. However, in practice, many factories often fall into three common misconceptions when lubricating bearings, resulting in poor lubrication and even accelerated bearing damage.
The first misconception is to lubricate based on time rather than condition.
Many factories are accustomed to lubricating their bearings at regular intervals (e.g., weekly or monthly), however, this practice often ignores the actual lubrication needs of the bearings. The only reason a bearing needs grease is to reduce friction, so as long as the grease is still lubricating well, there is no need to change or add more grease. The correct approach is to use ultrasonic monitoring technology to measure and assess the friction level of the bearing in real time to determine the best time to lubricate.
The second misconception is over or under lubrication.
Too much grease increases the pressure inside the bearing, pushing the rolling elements through the fluid film and against the outer ring, causing the bearing to run harder. Too little grease, on the other hand, fails to form an effective lubrication film, again accelerating bearing wear. To avoid this, factories should use ultrasonic monitoring technology to slowly add new grease as it is applied and listen carefully to the bearing to measure the drop in friction as the grease flows into the bearing. When the decibel level approaches a minimum and stabilizes, the proper amount of grease has been added.
The third misconception is to rely solely on subjective ultrasonic noise to determine the lubrication status of a bearing.
This approach is too subjective and lacks accuracy and reliability. The correct approach is to monitor the lubrication status of the bearing using an ultrasonic instrument with digital dB measurement capability, or even better, a device that provides multiple status indicators. These devices can provide maximum RMS and peak dB measurements, as well as parameters such as ultrasonic crest factor, to help us accurately determine the lubrication needs and health of the bearing.
By avoiding these three common lubrication pitfalls, plants can dramatically improve the operating efficiency and service life of their machinery and equipment. Ultrasonic-assisted lubrication technology offers significant advantages that calendar-based lubrication cannot match. It monitors friction levels in real time to ensure that bearings are running at their optimum; it also reduces grease and energy costs by optimizing grease consumption and storage practices. For factories, the right lubrication technology and methodology is not only the key to improved productivity, but also to sustainable development.