AE SIGNAL ANALYSIS DOI: 10.1784/insi.2011.53.8.
431
Energy-efficient hydrodynamic journal bearings by means
of condition monitoring and lubrication flow control
A Albers, H T Nguyen and W Burger
Paper presented at CM-MFPT 2011, the Eighth International Conference on Condition Monitoring and
Machinery Failure Prevention Technologies, Cardiff, UK, June 2011
Journal bearings are one of the most commonly used
engineering parts. State-of-the-art hydrodynamic journal
bearing lubrication is carried out by a constant oversupply
with lubricant; theory suggests a lubrication flow rate which
is up to 80% lower. This causes energy losses due to fluid
film friction in the unloaded areas of the bearing. Reducing
the lubricant flow, however, may lead to overheating of the
bearing or collapse of the load-carrying fluid film, both
resulting in failure of the journal bearing. A new approach to
safely reduce the lubricant flow by 80% is presented in this
paper, by using a broadband piezoelectric acoustic emission
sensor to detect ultrasonic structure-borne noise, usually
caused by metal-to-metal contact at mixed and boundary
lubrication conditions.
The method of structure-borne noise analysis has proven to
be suitable for detecting the occurrence of solid friction(1-4).
By combining structure-borne noise analysis with a closed-
loop control of a proportional flow control valve, a condition
dependent lubricant flow can be set. Thus, friction in the
bearing is reduced and, additionally, electrical energy in the
peripheral devices such as pumps can be saved.
1. Introduction
Journal bearings are one of the most commonly used engineering
parts. They are applied in many automotive engines or industrial
machinery, such as steam turbines. Due to their basic composition,
they are extremely inexpensive, easy to assemble and show low
wear rates while running under hydrodynamic conditions. However,
compared to standard ball bearings, they need a constant lubrication
supply (commonly oil), which requires at least an oil supply tank
and, in general, a pump by default. An additional disadvantage
is the power loss due to fluid film friction, which is proportional
to the velocity and dependent on the viscosity(5). Comparing the
theoretical lubrication amount calculated by Vogelpohl(6) with the
state-of-the-art according to VDI2204(7), one may realise an over
dimensioning by 400%. Intentionally oversupplying the journal
bearing has its reasons in machine safety aspects, as bearing failure
may lead to total machine failure and personal injuries. Doing so,
however, leads to higher power losses due to fluid film friction and
a raised delivery rate for the pump, resulting in an increased overall
power loss. Condition monitoring by means of acoustic emission
analysis may be a solution to both, maintaining machine safety and
reducing power loss due to fluid film friction.
A Albers, H T Nguyen and W Burger are with IPEK – Institute of Product
Engineering, Karlsruhe, 76131, Germany. Tel: +49 721 42371; Fax: +49
721 46051; Email: albers@ipek.uka.de
Insight Vol 53 No 8 August 2011
This paper presents a novel approach to safely reduce the
lubrication to its theoretical minimum, as suggested by Vogelpohl,
by means of in-situ condition monitoring.
2. Acoustic emission analysis in bearing
condition monitoring
The most essential damaging mechanism for hydrodynamic journal
bearings is wear as a result of boundary friction conditions due
to insufficient lubrication(8). Previous own works(1-4,9), as well as
numerous other sources(8,10-14), document the applicability of methods
based on ultrasonic structure-borne sound (acoustic emissions) for
detecting changes in the frictional characteristics of hydrodynamic
journal bearings. The frequency contents of these structure-borne
sound waves range from some Hertz up to several Megahertz(15),
but typically the ultrasonic range is particularly regarded. In
literature (for example Kolerus(16)), the range between 50 kHz and
2 MHz is often revealed as suitable since lower frequency ranges
are dominated by ambient noise and in higher ranges attenuation
increases considerably.
3. Required lubrication by Vogelpohl
A standard lubrication layout is based on DIN 31652 and VDI 2204.
Comparing the calculated required lubrication amount to Vogelpohl’s
theoretical assumptions, however, reveals an oversupply by almost
400% (see Table 1). Lubrication in a hydrodynamic journal bearing
mainly serves two purposes: cooling and enabling a load-carrying
lubrication film(6). Vogelpohl therefore differentiates between a
load-carrying lubrication flow QT and a cooling lubrication flow
QK. As QT cannot be easily determined, an equivalent lubrication
flow QV is being introduced as:
1
Q V = BUC ....................................(1)
4
with:
1 1 
Q T =  …  Q V .................................(2)
3 2
B = bearing width; U = circumferential speed; C = clearance.
Expression (1) is not dependent on applied forces, but is only
dependent on geometrical characteristics (clearance and journal
bearing width) and speed. Table 1 shows the required lubrication
calculated according to VDI 2204 and Equation (2) for different
shaft speeds.
Table 1. Calculated lubrication flow as a function of r/min and
journal bearing geometry according to VDI 2204 and Vogelpohl
n QVDI QV QT (= 1/3QV)
1000 r/min 197 mℓ/min 116 mℓ/min 39 mℓ/min
2000 r/min 296 mℓ/min 174 mℓ/min 58 mℓ/min
2000 r/min 395 mℓ/min 232 mℓ/min 77 mℓ/min
431
4. Procedure of tests metal-to-metal contact. However, for this application it was more
feasible to record the current rather than the ohmic resistance. This
The experiments were carried out on a test bench designed for ‘leakage current’ is later referred to as a dimensionless indicator
journal bearing tests. Figure 1 (left) shows a partial section in a for boundary conditions. In real life applications, however, this
three-dimensional view. The journal is seated in two supporting condition monitoring method is not suitable, as it is unlikely to be
bearings. A radial load is applied via the monitored bearing by a possible to electrically insulate a single shaft.
hydraulic cylinder. Each of the support bearings carries half of
the load applied as the monitored bearing is centrally positioned.
The monitored bearing was a lead-copper-tin based composite
material type Glyco40 with an inner diameter D = 61.32 mm
and a load-carrying width B = 21 mm. The journal diameter was
d = 61.205 mm. The two support bearings had similar dimensions
to the monitored bearing.

Figure 2. Journal bearing condition monitoring set-up (left)

and electrical circuit for lubricating film resistance measuring
(right)
Two series of experiments were carried out. The short-term
experiments were designed to estimate possible savings due to
fluid film friction reduction. The long runs are designed to show the
reliable performance of a closed loop journal bearing lubrication
flow control prototype running at QT.

5. Results
Figure 1. Journal bearing test-rig (left) and AE sensor mounting
position (right) Figure 3 shows an exemplary result of the short-term experiments.
The aim of these experiments was to determine the scale of
Shaft speed (n) can be varied from 150 to 3000 r/min. The possible drive torque reduction. Lubrication flow qOil was reduced,
shaft speed, drive torque (MR), radial load (FN) and journal bearing as displayed in Figure 3 (upper chart), at t1, t3 and t4. At t1, qOil was
housing temperature (T) were measured continuously during the reduced to a minimum amount QT (see Table 1). As an immediate
experiments. response, friction torque (MR) drops by approximately 9.4% (from
The acoustic emission (AE) sensor was placed directly at 1900 Nmm to 1720 Nmm). The same behaviour can be seen at
the monitored journal bearing housing to ensure the best signal t3 and t4. At t2 and t5, qOil was increased to its initial amount QVDI.
quality (see Figure 1 (right)). A broadband AE sensor type Kistler According to theory, the journal bearing is at risk of running in
8152B1(17) with associated amplifier type Kistler 5125B(18) was the boundary lubrication condition between period one, t1 – t2, and
used. The amplifier features an integrated third-order Butterworth period two, t4 – t5. Analysing the AE signal plot and lubrication
band-pass filter. The cut-off frequencies of high- and low-pass were condition monitor in period one, no major peaks can be found. In
set to 50 kHz and 500 kHz, respectively. The usable frequency an early stage of period two, the lubrication indicator shows a major
range of the sensor is 50 kHz to 400 kHz(17). The AE signal was excursion, indicating boundary lubrication conditions. However,
recorded by a high-speed A/D converter (National Instruments the AE signal shows no reaction. This leads to the assumption that
PCI 6251) at a sampling rate of 1.25 MHz. Due to the duration of metal-to-metal contact occurred for a split second but the lubrication
experiments and the resulting amount of data, the AE signal was film remained unimpaired. When lubrication flow is increased at t2
recorded discontinuously: every five seconds over a period of two and t5, the AE signal level rises. This effect does not agree with
seconds for the short experiments and every 30 seconds for a period theory, as increasing the lubricant flow should not cause boundary
of one second for the long runs. conditions. It is plausible that the peaks are caused by lubrication
The journal bearings were lubricated with oil of type FVA 3.
The support bearings and the monitored bearing were supplied by
different oil pumps. The lubrication flow was varied only for the
monitored bearing and kept constant for the others at qOil ≥ QVDI.
Figure 2 (left) shows the condition monitoring set-up. By
continuously analysing the AE signal and journal bearing housing
temperature, a computer controlled the lubrication flow (qOil) using
a proportional flow control valve. In this set-up, temperature was the
primary control variable and the AE signal secondary. If the journal
bearing housing temperature was Tjournal > 70°C, the lubrication
flow was increased step-by-step (each step was about 30 mℓ/min)
until Tjournal < 70°C. If a mixed lubrication condition was detected
by AE analysis, the lubrication flow was increased immediately to
qOil = qVDI. While running under hydrodynamic conditions, qOil is set
equal to QT. If a boundary lubrication condition should occur, then
qOil is to be increased to QVDI.
In addition to the AE signal, the lubrication film resistance was
recorded (see Figure 2 (right)). While running under hydrodynamic
Figure 3. Short-term experiment with reduced lubrication:
conditions the shaft and the bearing are always separated by an oil lubrication flow and torque (upper) and AE signal energy
film. As oil is not conductive, the ohmic resistance should therefore and lubrication condition indicator (lower), F = 750 N,
be infinite. Thus, the ohmic resistance may be used to indicate n = 2000 r/min

432 Insight Vol 53 No 8 August 2011

flow turbulence. However, further investigations are necessary to
explain these peaks satisfactorily.
Figure 4 shows an exemplary result of the long-run experiments.
The aim of these experiments was to apply journal bearing condition
monitoring by means of AE analysis as a closed-loop autonomous
energy efficient lubrication flow control system. Figure 4 (upper
chart) shows the friction torque (MR) and lubrication flow (qOil). The
journal bearing lubrication was initially set to qOil = QV, followed
by a reduction to qOil = QT at t1. Due to the reduced amount of
lubrication, the bearing housing temperature increased from 45°C
to 47°C. The rotation speed (n = 1000 r/min), radial force (Ø FN =
890 N) and supply oil temperature (Ø TOil-Supply = 30°C) were kept
constant throughout the experiment.
Figure 4 (lower chart) shows the AE signal energy and
lubrication condition indicator. A minor excursion in the condition
indicator signal can be found throughout the experiment. However,
analysing the AE signal and MR plots reveals no evidence of metal-
to-metal contact, leading to the conclusion that the excursions may
have been caused by particles in the lubricant.
Figure 4. Long-run experiment, n = 1000 min-1, FN = 890 N:
lubrication flow and torque (upper), AE signal energy and
lubrication condition indicator (lower)
Analysing the friction torque and AE plots closely, it is evident
that the behaviour is very similar. Excursions in the AE signal
correspond to peaks and valleys in the friction torque plot. This
supports our own previous works(1-4) and indicates that AE analysis
is a reliable method for detecting and monitoring friction. As a
conclusion, the experiments show that the prototype closed-loop
lubrication flow control system operated surpassingly.
6. Conclusions
A total power loss reduction of around 10% has been experimentally
verified as a result of reducing the lubricant flow rate to a minimum
value, as calculated using Equation (2). It should be easily possible to
reduce the power loss due to lubricant friction by up to 20%.
The long runs have shown the applicability of a closed-loop
lubrication flow control system by means of AE signal analysis.
The journal bearing has been safely operated at around 80% less
lubrication flow, as dictated by VDI2204. As the bearing is being
closely monitored, AE signal analysis may even lead to increased
machine safety due to inherent condition monitoring.
As the energy savings of the pumps are not included, the overall
sum should be even higher. However, this is only applicable for fast
running journal bearings with light load and high speeds, typically
for Sommerfeld numbers SO < 1.
The impact on the journal bearing viscous damping and
temperature management has not been investigated in this paper
and must be focused on in future research.
Insight Vol 53 No 8 August 2011
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