Bearings are among the most important components in the vast majority of machines deployed in any type of industries. Exacting demands are made on their load carrying capacity, running accuracy, noise levels, friction and frictional heat, life and reliability. Therefore, bearings are playing such a prominent role in every industry. Service life of bearings are mainly depending on ambient conditions such as

  • Operating conditions like loads, Oscillations and vibrations
  • Contaminants
  • Temperatures

These factors have an impact on the service life and must be taken into account when calculating lubricant quantities and lubrication intervals. The greater the load or the influence of ambient conditions, the more lubricant is required to guarantee optimal lubrication.

Roller bearings - loads and movements of Roller bearings are transferred by means of rollers, arranged between an outer and inner race. If these metallic components make direct contact with one another due to improper lubrication, the contact causes undesirable friction, wear and damage, which may lead to bearing failure.

Sliding bearings – Sliding bearings are designed to carry loads axially or radially. So, the moving parts of Sliding bearings are in direct, sliding, linear contact. They can accept greater forces than roller bearings, but are more heavily impacted by wear due to the greater friction. If the formation of lubrication film is inadequate, it can cause more frictional losses which includes heat and wear and results in bearing failures.

Bearing damage, resulting from improper lubrication or contamination in the bearing, can result in consequential damage of machines and its parts.

Only regular and efficient lubrication ensures that these bearings function correctly and reliable use of machines.

linear / sliding guides

Linear Guide Systems are designed to move materials in X-axis, Y-axis and sometimes in Z-axis accurately and smoothly in industries. Generally, it handles the movement of materials in automatic manufacturing processes, ensuring the materials are correctly oriented, even at high speeds and offer a wide range of modern industrial applications. Two basic types of linear guides are predominantly used in industry today. These types are - rolling element linear motion bearing guides and sliding contact linear motion bearing guides. The main distinction between the two is how the motion of the linear block occurs along the linear rail.

For Linear Guides, lubrication separates the bearings (ball or roller) or sliding plates from the raceways / guides, minimizes friction and wear, dissipates heat, and prevents corrosion. It also promotes smooth running of the seals and reduces seal wear, ensuring their effectiveness in keeping the bearing lubricant in and keeping contamination out.

A continuous supply fresh lubricant is a basic requirement in Linear Guide Systems for achieving the projected service life. The lubrication requirements of the different applications vary considerably. Due to its special design and varied use, lubrication points in these systems present a following challenges for efficient and preventive maintenance.

  • Lubrication points can often only be accessed with assistive equipment and system shutdown.
  • Many lubrication points must be lubricated exactly according to requirements while the equipment is in operation.
  • Different lubrication points require different lubricant amounts.

Hence, Improper lubrication can cause equipment failures and reduces productivity and cost effectiveness. Lubricant (grease or oil) supplied reliably, in the correct quantity and quality while the equipment is in operation minimizes friction and wear and thus prevents premature failure of the guides.

threaded spindles

Threaded spindles, also called as Roller Screws, are machine elements that together with other elements, serve to convert a rotary movement into a translatory movement. It consists of a ground spindle and the threaded nut which is equipped with rollers. The special geometry of the thread and the rollers characterize the Roller Screws. The use of rollers with grooves on their outside diameter and the hereby resulting contact areas as well as the number of contact points permit a high axial load capacity. Roller Screws are installed to handle the materials and tools in vast range of industrial applications especially in machining centres.

A key prerequisite for the low-wear (or even wear-free) operation of a Roller Screw is the reliable separation of the surfaces of the rolling elements and the ball raceways with a proper lubrication. The proper lubrication to be performed to achieve increased wear protection in the ball contact points and to effectively prevent any surface damage in the event of frictions and loads.

Followings are the key factors that influencing the service life of threaded Spindles

  • Dust, Dirt and other contaminations
  • Speed, Oscillations and vibrations
  • Frequent Start and Stop
  • High Temperatures
  • Extreme Load

The proper lubrication while in operation can prevent the Roller Screws from contaminants and reduce contact between rolling and sliding surfaces results in reduced heat generation due to the frictions and loads and enhanced service life.

open gears and chains

Gears and Chains are used to transmit power and movement in industries. There are types of arrangement such as two-dimensionally movable and one-dimensionally movable.

Wear is inevitable at various Chain friction points and Gears. In Chains, it often is incorrectly referred to as stretch. This elongation should not be more than 3 to 5% of chain pitch to prevent ride up and possible jump off. Once chain elongation has exceeded this value, wear will accelerate to further damage the chain and chain wheel/sprocket.

Preventive maintenance of Chain and Gear systems are integrated with the following challenges,

  • Pollution, high Humidity, high or low ambient Temperatures
  • Very high Loads, high Speeds, high Power transmission, Oscillations and Vibrations
  • Uneven movements, contaminations of environment
  • Access of lubrication points are not easy always and time-consuming

Insufficient lubrication is detrimental to chain life, causing excessive wear, noise and vibration. These conditions are potential sources of energy loss that contribute to an overall inefficient Chain and Gear system. Over-lubrication can affect the integrity of chain and Gear systems and cause the environment pollutions, in addition.

Hence, proper lubrication is essential for maximum Chain life and Gear systems performance. The optimal lubricant also can reduce noise levels and reduce energy consumption.