Ultrasound Technic
Ultrasound technic is a method of using high-frequency sound waves to measure the friction and impact of bearings. It can help detect bearing health condition by indicating the level of lubrication and the presence of damage or defects. Ultrasound can provide the earliest warning of bearing failure, even before temperature and vibration increase. Using ultrasound, the decibel level (dB) reading is the best indicator of bearing health. Ultrasound can be used on all bearing speeds, even on extremely slow-speed bearings, and is simple to use.
Under lubricating or overlubricating a bearing can destroy it and bring production to a halt. Although there’s always going to be a certain amount of friction, maintaining just the right quantity of lubrication will keep it at an acceptable level.
IoT drives an increase in ultrasound advancement and capabilities
A daunting eighty percent of premature bearing failures can be traced to over-or under lubrication. By combining an IIoT system with real-time friction and impact monitoring, ultrasonic technology can catch the signs of a bearing defect early. Ultrasound measures the decibel or sound level of friction, and impacting indicates it needs lubrication.
In addition to over-or under-lubrication, bearings also fail due to contamination, using incorrect grease, material defects, and indirect causes such as improper machinery mounting. But over greasing often has the most detrimental effect on bearing life.
The ISO29821-1 standard dictates when to lubricate a bearing based on decibels above your established baseline. For example, an +8 dB increase indicates that it needs lubrication. A 16-decibel reading indicates early onset failure, and a 35-decibel increase means it’s close to failure. This range changes somewhat depending on the bearing type.
Setting and trending near the baseline
When applying ultrasound technology, use the recommended thresholds and then trend the sensor data over time to ensure you’re getting an accurate baseline. This sensor system software enables you to watch the arrow and status move downward or upward in real-time using a laptop, mobile device, or computer. Depending on your setup, you can add grease remotely using an automatic lubricator.
To implement ultrasound technology for bearing monitoring in your company, you need to follow some steps, such as:
- Identify the critical components and systems for testing, such as plain bearings, journal bearings, thrust bearings, etc.
- Select the right products, such as sensors, software, and accessories, that are compatible with your equipment and network.
- Install the sensors on the test points and take initial readings for benchmarking the baseline dB level of the bearings.
- Document the test points, readings, components, and products, and train the personnel to properly operate the sensors and software.
- Monitor the change in dB level, indicating the health of the bearings, and check the ISO rules for lubrication and damage levels.
- Establish attainable milestones for integration and evaluate the effectiveness and efficiency of the ultrasound technology.
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