Avoid Over-Lubrication of Bearings Using Acoustic Grease Gun and Grease Meters

The most common problem faced while using a grease gun is determination of the lubrication frequency of greasing or re-lubrication. Despite the fact that most original equipment manufacturers (OEM) provide a chart mentioning the greasing times and amounts, more often than not, these aren’t enough. They are just general guidelines and several variations need to be implemented based on existing conditions of the bearings. Additionally, the amounts, method and intervals of greasing change from motor to motor; even ones that are manufactured by the same producer. Technicians also need to consider the equipment that has not been supplied with all this essential information. Certain equipment is also bound to fall outside the common ranges and methods of greasing and require only specific greasing techniques. So how does one solve these issues?

The first thing one has to do is calculate the quantity of greasing using the following formula:

Amount of Grease (g) = 0.005 X Bearing Outside Diameter (mm) X Total Bearing Width (mm).

For this purpose, one needs to know the bearing outer diameter. The frequency of greasing can also be determined based on the speed and load values that are acceptable for the bearing. Trial and error might be needed in many cases, but extreme care should be taken so that the bearing is not damaged due to errors in these calculations.

The great news for equipment owners is that there are many sophisticated devices available that help take away all the trial and error as well as the guesswork out of the quantity and timings of greasing. Sonic and ultrasonic grease guns help technicians determine when the bearing has had enough greasing. This can help avoid over greasing and protect the bearing’s life. They basically utilize a transducer that is fixed on the end of the grease gun. This helps send a signal to a processor that converts ultrasonic sound-waves into audible ones. Trained users can use such devices to understand greasing frequencies that work best for particular types of bearings.

In addition, grease gun meters are also very useful in cases where you know the exact amount of grease as prescribed by the OEM. These quantities are usually in grams and can be detected by grease meters. The drawback of grease gun meters is that no indication is given to the user whether the quantity is just right. Hence experts recommend using an ultrasonic grease gun with the meter combination. Together this is the best technique to comprehend whether a bearing has had enough lube. Once you gain more experience and learn to sense the amounts of grease per equipment, you will be able to correctly determine the frequency of greasing. Machines do have this innate sense of ‘telling’ us when they want greasing; we only need to listen!

Another technique is the use of autolubers which are available in refined microprocessor- controlled form as well as traditional electromechanical form. Both these kinds can help control the flow of grease. Once you have started using ultrasonic grease gun with a meter, you can easily calculate the dispensing rate of the autolubers.

Additionally, you need to update your greasing techniques and programs every now and then. You also need to monitor the conditions in which machines operate as these are likely to change. The ambient temperature and vibration frequencies of bearings are important indications to understand whether your greasing techniques are effective or not. An acoustic grease gun can help you take away great deal of hassles involved in the process.

Source by Dipa A M

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