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Boost roller bearing life using PM and PdM strategies

Premature roller bearing failure

Learning to troubleshoot bearing problems is a crucial part of any maintenance program. As many as 13% of industrial motor failures happen because of bearing failures. Moreover, 60% of equipment breakdowns involve bearing wear.

Most defects result from a combination of failure modes, and each failure is usually due to a mixture of causes.

 

Vibration: A chief precursor to bearing failure

Usually, before bearings fail, the problem appears in the form of vibration. For example, roller bearings will cause vibration each time they pass over a damaged or pitted roller bearing race. Without being harmful or invasive, vibration analysis provides the most detail about what is happening inside machinery by detecting minuscule changes in acceleration, direction or velocity that may indicate bearing wear, installation error or other mechanical problems.

Wireless condition monitoring vibration sensors installed on a bearing housing can provide maintenance teams with actionable data. Technologically advanced tools can help further ferret out more complex issues that might show up in the overall vibration analysis. It can then be used to decide whether additional analysis is required and if relubrication, repairs or replacements are needed.

Infrared (IR) thermography can also be used for oil analysis to discover if wear particles or other contamination-causing issues are present in the roller bearing. Thermal imaging sensors can be set in place to monitor equipment condition safely. Measurements are taken from a distance and uploaded to the cloud, where technicians can view them on a smart device, such as a mobile phone, tablet or computer. The data can then trend temperature changes over time and help determine if bearings are operating optimally or headed for a breakdown.

 

Boost roller bearing life using PM and PdM strategies

Fortunately, by carrying out preventive maintenance tasks, roller bearings have a better chance of reaching their full potential. When predictive maintenance tools, such as vibration sensors, are integrated with computer maintenance management software (CMMS), maintenance teams can set acceptable boundaries for equipment operation, import and view continuous readings and graph results. Additionally, the system can be configured to automatically trigger an email or generate a work order — should equipment exceed parameters. With cloud technology, maintenance and reliability (M&R) teams can view data in real time from anywhere, any time.

Premature roller bearing failure can affect business, the environment and personnel — should the bearing cause an explosion. Even the most comprehensive maintenance program can result in undetected faults, leading to unexpected failures. However, through proper care and with the help of proactive maintenance strategies, M&R teams can further ensure roller bearing reliability. 

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