Looking back at the capabilities of ultrasound in the past four years, it is clear that manufacturing facilities have witnessed tremendous changes in technology. Recent innovations not only take a new stand on how to monitor rotating assets, but also maintain them by lubricating bearings wherever a web browser can be opened in the world. This article will provide a better understanding of how the technology behind structure propagation has evolved.

In order to use ultrasound correctly, please listen to the changes in the friction level in the rotating device at a specific frequency (kilohertz [kHz]) setting, and then monitor the decibel (dB) level over time. Move according to the delta value of dB, because it shows that the friction is 8 dB higher than the previously set baseline, so it needs lubrication now. 

Within 16 dB above the baseline, the failure phase can be heard. An increase of more than 35 dB will put the asset in a catastrophic failure stage. 1

For decades, before the 1990s, many users regarded ultrasound as a troubleshooting tool or a simple compressed air and gas leak detector. Are people still using ultrasound for troubleshooting? Absolutely. This is a good way to quickly identify potential problems with the motor or drive. Many people may walk into the production workshop, touch a piece of equipment, and think: "Yes, this sounds different. We are going to pull this this weekend." If not, please grab the ultrasonic device that propagates the structure and try it. Because it is eye-opening. One of the main reasons it is called a troubleshooting tool is because the ultrasound equipment is purely analog. It is suitable for this method, but users cannot save or store any data, which means that any document must be completed by hand with pen and paper.

In the early 1990s, the era of digital ultrasound came. The software now allows users to create bearing routes to upload to the device. This enables users to use compatible software on the local computer to record dB levels to trend alarm levels over time. Users can now check whether their bearings require grease after running the ultrasonic path. This can help users understand the dynamics of the asset and understand the position of the equipment on the IPF (installation-potential failure-failure) curve (Figure 1).

This installation-potential failure-failure (IPF) graph can be used to help understand which technologies can detect anomalies or potential failures. When talking about lubrication and bearings, ultrasound is at the top of the IPF curve. Over time, if a bearing lacks attention, the asset will eventually enter a state of functional failure. At this point, the asset may hear noisy sounds, feel hot to the touch, or even vibrate physically. 

The more users fall into the curve of catastrophic failure, the higher the cost of replacing or replacing assets due to production interruptions. This may also mean that users must spare parts overnight, unless they are already in inventory. At this point, the mandatory overtime hours are almost given in order to restore the assets to operation.  

A common problem with route-based data collection is time. Usually, every time a user goes out to collect data from their assets, it turns out that most of them can, while a few may need attention. Facts have proved that friction is not the enemy, but time is the first public enemy. It took a lot of time:

Ask, "Is there a way to save time and stay to the left of P before the failure begins?" Look at how ultrasound has developed in the last year. 

Modern ultrasonic equipment has completely changed the way users monitor and maintain motors, drives, and pump bearings. The ability to monitor 24/7 online throughout the year has always been an important moment in the technical field, but why stop there? Ultrasonic has opened up a way to not only remotely monitor rotating assets, but also remotely lubricate bearings on motors, drives, or pumps using a single-point lubricator from anywhere in the world. think about it.

Ultrasound can reduce premature bearing failure by 80%2, for example:

By using friction levels from remote sensors and establishing prescribed alarms, users can now order a single-point lubricator to lubricate the bearing manually or automatically to lubricate the bearing from anywhere with internet access until the algorithm is met. This solves 80% of the premature bearing failures listed above. The technology is monitoring when grease is needed and injecting a small amount of grease until the friction level falls back to the baseline without over-lubrication. This ensures that the user will stay on the left side of P (Figure 3). 

Users no longer need to worry about remembering the time they last lubricated their assets because of the progress of the cloud service software tracking data, such as dB, the amount of lubrication in the single-point lubricator, the amount of grease distributed, when the grease was distributed, and the end of dB The level is. 

The user will know what kind of grease is contained in the single-point lubricator because it is pre-selected. Finally, installing a single-point lubrication system on rotating equipment can prevent bearing contamination. 

Ultrasound is no longer just a troubleshooting technique. In fact, the advancement from field testing to route-based data collection to 24/7 monitoring, being able to maintain bearings without worrying about causing major premature bearing failures, shows how advanced this technology is. Ultrasound has become a true plug-and-play technology that can reduce premature failures by 80%. Using the wrong lubrication, not changing the lubrication for a long time, improper lubrication and lubrication contamination are now faults of the past.  

The alarm value is an example in the ISO 29821-1 section 8.5 evaluation standard.  

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Chase Sasser has been the Southeast Regional Manager of UE Systems, Inc. since 2011. He has obtained Ultrasonic Level 1 and Certified Maintenance and Reliability Specialist (CMRP) certification. He co-founded and currently serves on the board of directors of the SMRP Alabama chapter, serving as the director of communications and former chairman. Sasser graduated from the University of Alabama. You can contact him at chases@uesystems.com. For more information, please visit www.uesystems.com.