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Get A Handle On Grease Lubrication
Get A Handle On Grease Lubrication
Get A Handle On Grease Lubrication
Ray Garvey, Emerson Process Management Tags: greases, bearing lubrication, grease guns
at the roller-to-cage interface is first lost. This results in high friction caused by sliding-action at the cageto-roller interface. This is thought to be true because a 20 micron oil film is required to support the hydrodynamic lubrication at the roller-to-cage interface (see Figure 1). Conversely, only a one micron oil film is required to support elasto-hydrodynamic lubrication at the roller-to-race interface (see Figure 1). As such, it is believed to typically be lost later in the lubrication failure progression. Because the roller-to-cage interface is lightly loaded, high-friction might not immediately equate to high wear. Eventually, however, boundary lubrication conditions take their toll on the cage and adhesive wear begins to occur resulting is secondary damage and accelerated progression toward failure. If the bearings load and speed are high, the rollers may also begin to overheat. In the absence of an adequate oil film between the roller and race, the result is increased friction and torque that is focused upon the surfaces of the roller, race and cage and leads to catastrophic damage. Our stated goal for condition monitoring is to detect the early signs of lubricant starvation and take corrective action before the onset of bearing damage. Because of sampling limitations using conventional oil analysis, we turn analytical techniques that examine the mechanical and thermal signatures of the component to identify the telltale signs of friction. One such technique involves the use of a multifrequency sonic / ultrasonic measurement with calibrated decibel (dB) output quickly identify bearings starved for grease lubrication. The premise is that a change in the amplitude (dB) of sonic / ultrasonic energy signifies the presence of a problem, while the frequency at which the change occurs indicates the problems nature (see Figure 2). It should be noted that unlike vibration analysis, the target frequency is not a function of the machines running speed (rpm). Figure 3 depicts one such device for collecting sonic / ultrasonic readings.
Field Verification
A study of 13 different rolling element bearings on the conveyor line at a food processor plant was undertaken to test the effectiveness of sonic/ultrasonic analysis in detecting poor lubrication. The bearings under investigation were scheduled for regular greasing. Six of the bearings evaluated were very accessible for re-lubrication. The other bearings in the study were not easily accessed for relubrication. Three measurements were collected before and three after greasing each bearing to determine the Peak Hold (PH) and Average Value (AV) dB readings at 4 kHz (sonic) and 30 kHz (ultrasonic) frequency ranges. Temperature measurements were also collected for each of the bearings. Headphones were also used during data collection, but interference due to plant noise caused diminished resolution. The calibrated dB reading, especially the AV readings were deemed more reliable. The easy-to-reach bearings indicated no significant difference before and after greasing the bearings, suggesting that they have been effectively lubricated all along. The hard-to-reach bearings, on the other hand, did show before-after differences on several bearings. One bearing was particularly hard to reach for re-lubrication, and it showed a dramatic variation in the before after readings as is summarized in Figure 4. The data from the bad-actor bearing revealed the following: This bearing was showing only slightly greater than normal AV impact energy (4 kHz) reduced after greasing suggesting that significant damage to the bearing had not yet occurred. The AV dB reading at the 30 kHz frequency was much higher than average suggesting friction at the roll-to-cage interface due to lack of adequate hydrodynamic lubrication. Upon lubrication, the reading dropped from well above average to well below average suggest ing that lubrication was re-established.
4) Collect thermometric data for the bearing. 5) Diagnose readings as follows: If the 30 kHz dB reading and the temperature reading are OK, the bearing is well lubricated. If the 30 kHz dB reading is OK but the temperature is more than 10 F. over normal, the bearing is probably over greased. Relieve if possible. Note: an over-lubricated bearing might show a slightly elevated 30 kHz dB reading. If the 30 kHz dB reading is in alarm, slowly grease the bearing allowing time for the lubricant to distribute in the bearing. Continue to slowly add more grease as long as the 30 kHz dB reading continues to drop. When the bearing reaches the normal level, discontinue adding grease. If the 30 kHz dB reading does not drop during the addition of grease, the problem may be a blocked lube delivery path or a non-lubrication related problem. In such a case, inspect further using vibration analysis, thermography, etc.
Conclusion
Used routinely, sonic / ultrasonic analysis can play an important role in ensuring proper lubrication of greased bearings. While not conventional oil analysis the technique fills an important gap where conventional oil analysis falls short. Proactive in nature, the technique effectively identifies when lubrication is required. Properly applied, it proves an effective defense against over or under lubrication. It also enables those hard-to-reach bearings to be greased on-condition only, avoiding unnecessary cost and risk or discomfort to the lubrication technician. This experience-based technique could become even more valuable as we continue to learn about and understand the relationship between inadequate lubrication and sonic / ultrasonic measurement. References: 1) Neale, M. and D. Summers-Smith (1997) Improving the Reliability of Machines by Understanding the Failure of their Moving Parts, Master Series Course Book, CSI: Knoxville, TN, October. 2) Robinson, J., J Van Voorhis, K. Piety and W. King (1999) Machinery Surveillance Employing Sonic/Ultrasonic Sensors, Proceedings from Reliability Week, CSI: Knoxville, TN.