… by Sarvadnya Kulkarni, CEO, General Instruments Consortium
Industrial machines are workhorses that keep production lines up and running. In factories, there are turbines that spin, rollers that press, pumps that circulate fluids, and motors that power conveyors–not to mention a host of other mechanisms. All these are working; however, one thing that is in the back of all of them is keeping machines well-lubricated.
It also reduces the effects of friction and the resulting heat buildup caused by movement in the system. If lubrication is not working correctly in the system, the effects can be devastating in a short while. Therefore, even though lubrication is an important aspect of equipment reliability, maintenance personnel do not want anything to go wrong with lubrication.
However, conventional lubrication systems are still dependent upon fixed maintenance tasks or visual checks. Maintenance personnel can be required to grease bearings every 30 days, for instance, or to check lubrication reservoirs every week to ensure they are filled.
This seems like a sensible thing to do, but machines tend not to behave in this predictable manner. Loads tend to increase and decrease, temperatures increase and decrease, speeds increase and decrease, so the need for lubrication also increases and decreases.
That is, lubrication according to schedules rather than actual requirements is becoming less and less related to modern equipment. Hence, it has paved the way for precision sensing technology to revolutionize maintenance.
Beyond Scheduled Lubrications
There are risks associated with lubrication on both extremes. Overlubricating could cause excessive overheating, seal deterioration, as well as attraction of contaminants. On the contrary, insufficient lubricating lubricants could cause accelerated wear tear, overheating, as well as component failure.
Experienced techs will do the best job possible to assess the situation, but the subtleties of lubrication can be problematic and are not always assessed until problems become apparent.
How Sensors Change Lubrication Philosophy
The use of precision sensors enables machines to “communicate” their lubrication status. In that case, instead of relying on human judgment or scheduled checks, precision sensors will monitor and report the key parameters in real time.
These parameters define when lubrication is required and how much of it. The lubrication process transitions from a reactive form of maintenance towards predictive maintenance, bordering on autonomous.
The key to intelligent lubrication is being able to spot trends before a point of failure is reached. Clearly, spotting problems in lubrication sooner means that corrections are simpler and that equipment stays in operation for a longer period of time.
Important Types of Precision Sensors Used in Lubrication Systems
Various sensor technologies can detect different parameters related to the performance of lubricating. The common types are:
- Temperature Sensors
Heat is also an excellent lubrication effectiveness indicator. If bearings and gears are running hot, it may indicate increased friction and possibly insufficient lubrication. Temperature sensors placed near points of lubrication enable the system to automatically initiate lubrication cycles as the temperature increases.
- Vibration Sensors
Excessive vibrations are often a precursor to mechanical failure. Vibration sensors have a high degree of accuracy, enabling the measurement of minute variations that would be difficult to detect manually.
Pressure and flow rate measurements in the lubrication system confirm whether lubricants are supplied to each lubrication point. Absence of pressure or irregular flow rate measurements could signal obstructions in the lines or leaks in the lubrication system.
- Oil Condition Sensors
Lubricant health can deteriorate due to oxidation, particulate, moisture ingress, and temperature extremes. Oil condition sensors enable monitoring of lubricant health based on viscosity, cleanliness, and dielectric properties. By this, oil lubrication changes can be ensured to occur only when required.
- Level Sensors
These sensors protect against the lubrication reservoir drying out or overflowing. Constant, or continuous, level sensing prevents a reduction or increase of lubrication into the oil galleries, thus minimizing air entry into the lubrication lines.
When combined, these sensors provide an overall system status of lubrication conditions, which was not possible before.
What is “Intelligent” About Lubrication
Lubrication can be made intelligent by incorporating control with lubrication monitoring. This means that lubrication systems can automatically react to actual conditions rather than waiting for human response.
Characteristics of Intelligent Lubricant include:
- Lubrication caused by real conditions of operation
- Optimized volume and rate of lubrication
- Predictive maintenance notifications produced by way of trend analysis
Automated shutdown options in critical lubrication situations
- Historical logging for maintenance planning
Such developments fit into the general digitalization trend where machines respond dynamically to ensure optimal performance.
- Benefits of Industry
The deployment of precision sensors in the lubrication system provides a variety of benefits.
- Less Friction and Increased Life
Lubrication keeps the metals from making contact. It reduces friction. Lubrication application is automatic before damage.
- Improved Equipment Availability
If Lubrication problems are noticed early, then the chances of Break Down become low, and Downtime increases.
- Lower Maintenance Costs
The costs of maintenance can also be reduced by protecting against failures and by minimizing manual lubrication.
- Benefits of Greater Energy Efficiency
Less friction means motors and drives use less energy—this is an enforceable cost saving.
- Safer Working Conditions
Failures in machines or overheating can lead to potential dangers. This problem can be overcome by monitoring.
- Decreased Lubricant Consumption
This will ensure that the amount of waste generated by precise application is minimal. This will help achieve the environmental objectives
These improvements will multiply over time, thereby facilitating increased productivity and dependability.
Application Areas of Intelligent Lubrication
Industries involving the use of continuous/heavy-duty equipment have great benefits, namely:
- Steel and metal processing
- Power generation
- Cement plants
- Automobile manufacturing
- Paper mills & pulp mills
- Chemical processing and refineries
- Mining & processing of minerals
Practical Considerations Before Adoption
Some of the key factors include:
- Sensor Durability
The sensors also have to endure demanding operational environments, such as heat, vibration, dust, moisture, and chemicals
- Integration
The controllers have to integrate seamlessly with sensors and lubrication pumps. Their integration with SCADA or PLC is always an added advantage.
- Calibration and Maintenance
The use of regular calibration prevents a degradation of the sensors’ accuracy. It is essential for the upkeep team to plan the calibration sessions into them.
- Cybersecurity and Data Integrity:
As lubrication system solutions go digital, protecting control logic and sensor information is critical.
- Economic Evaluation:
The upfront costs should take into account factors such as minimized downtime, increased life of components, as well as minimized maintenance.
- Training Requirements:
People involved in maintenance should have some knowledge of sensor pattern interpretation and alerts. This is required for successful implementation.
Looking Ahead
Historically:
The adoption of precision sensors in lubrication systems marks the beginning of additional networking and auto-correcting systems. The latest technologies in the field, such as wireless sensor networks, micro-scale oil analysis sensors, and energy-harvesting sensor modules, promise continuous ease in installation and expanded applications.
With advancements in sensing and control technology, there may come a time when lubrication systems become self-sufficient, learning continually through experience.
Conclusion:
Lubrication is, and will remain, one of the basic cornerstones of reliability. Nonetheless, the conventional schedule-based approach to lubrication can fail when the operating conditions become more sophisticated. This is where the role of precision sensors comes into play. Based on real-time monitoring of temperature, vibrations, flow rates, oil condition, as well as other parameters, lubrication systems can satisfy a particular demand about the quantity of lubricant required. Such a technology aims to cut friction, reduce downtime, as well as save lubricants. The intelligent lubrication system that can be made possible with precision sensors represents a major advancement towards achieving sustainable industrial processes.
