"user manual"
Contents
1. Condition Monitoring of Greases in Rolling Bearings Demand controlled relubrication by means of grease analysis during operation SCHAEFFLER Demand controlled relubrication Higher cost effectiveness For your success Local competence worldwide presence Further information Foreword Incorrect lubrication is a major cause of bearing failure Through correct monitoring ofthe grease condition it is possible to see the point at which relubrication is required before damage occurs in the rolling bearing With FAG GreaseCheck it is possible to see the actual requirement for relubrication based on the special electronic evaluation system This means that grease lubrication can in future be carried out as a function of condition and not simply as a function of time Against the background of the fact that 95 of rolling bearings are lubricated using grease and approximately two thirds of bearing fail ures can be attributed to incorrect lubrication demand controlled relubrication is valuable and also give savings in resources Through greater practical application of tribological knowledge it is possible to make considerable savings in the following areas reduction in failure times that can be attributed to operational malfunctions lower lubricant costs lower costs for maintenance and replacement parts reduction in plant costs through increased efficiency levels In the long term the use of FAG GreaseCheck gives hig2. measurement Air inclusions can lead to incorrect measurements Tests carried out on the rolling bearing lubricant test rig FE8 in accordance with DIN 51819 1 have shown that the sensor must not record grease in direct rolling contact The areas adjacent to the raceway also contain highly homogeneous grease conditions As a result comparable measurement results can be obtained 0001A684 8 TPI234 Schaeffler Technologies Characteristic changes Grease condition t time I grease condition good II grease condition borderline III grease condition inadequate Type of load Thermal 3 Mechanical Thermal and mechanical Figure 5 Grease conditions Monitoring of the grease is carried out on the basis of characteristic changes for automatic condition assessment FAG GreaseCheck measures four parameters relative ageing relative turbidity relative water content current temperature of the grease The grease condition is a synthetic characteristic value and is deter mined from the total and weighting of the parameters ageing tur bidity water content and temperature Based on these parameters an analogue signal I 4 20 mA is generated in the electronic evaluation system from which the customer can quickly and easily see the condition of the grease Figure 5 A limit value can also be set in the form of a trigger threshold to generate a digital signal that indicates whether the grease condition
3. DC 24 20 CAN Bus connection Protection class 3 Mass Sensor head and cable 680 Sensor head g 30 Current Typical mA 43 consumption Maximum mA 250 Cable length of electronic evaluation system mm 5 000 twisted pair shielded Cable length of sensor head mm 800 Diameter of sensor head mm 5 1 The switching output must be subjected to a load such that it carries a minimum of 3 mA and a maximum of 150 mA 14 TPI 234 Schaeffler Technologies Schaeffler Technologies TPI234 15 Product overview Services Mounting _MOUNT HOUR Lubrication ARCA PUMP Condition monitoring CM HOUR ENGINEER N N A lt t S Ss 16 TPI 234 Schaeffler Technologies Services In addition to FAG GreaseCheck Schaeffler can provide numerous solutions for your specific requirements Here are some examples from the product portfolio of Schaeffler Industrial Aftermarket Mounting Our experienced fitters can support you in the mounting and dismounting of rolling bearings and advise you on the selection of suitable mounting tools Correct mounting is an essential precondition for achieving the maximum operating life of bearings In the case of the London Eye Schaeffler supplied the rolling bearings and carried out the mounting operations Figure 1 ea Figure 1 Double row FAG spherical roller bearing in the London Eye Lubrication Unsuitable lubrication can impair the operating
4. G Grease Sapphire glass 9 Cast material Figure 3 Design ofthe sensor head The penetration depth of the signal extends from the surface of the sapphire glass to a few millimetres into the grease Figure 3 The optimum mounting position will vary from one application to another The important factor here is the knowledge of the Schaeffler application engineers who can specify precisely the position at which the grease sensor should be mounted in the particular application d 4 5mm 0001A692 Schaeffler Technologies TPI 234 7 Analysis ofthe grease condition Figure 4 Rotationally symmetrical irradiation of the grease Condition monitoring of greases in rolling bearings The condition of the grease during ongoing operation of the rolling bearing is determined by means of an optical near infrared reflection method For this purpose the sensor head is immersed in the grease The know how involved lies not only in the design of the sensor but especially in the evaluation of the measured signals The method used involves the rotationally symmetrical irradiation of the grease at an angle of 45 using certain wavelengths within the infrared spectrum by the sensor Figure 4 A cable provides communication between the sensor head and the electronic evaluation system The measurement depth of the grease sensor extends only a few millimetres into the grease There must be grease directly in front of the sensor for
5. ancillary equipment power generation The innovative system combines grease and vibration diagnosis with a lubricator that is controlled by the monitoring devices In this way any critical change during ongoing operation can be detected and rectified before damage occurs in the rolling bearing In particular plant that is difficult to access or failure critical can be comprehensively monitored and always provided with a optimum supply of grease without the need for someone to be present on site Figure 8 0001A698 For installation the important factor is the knowledge of the Schaeffler application engineers who can specify precisely the position at which the grease sensor should be mounted in the particular application Schaeffler Technologies TPI 234 13 Technical data for FAG GreaseCheck Technical data Condition monitoring of greases in rolling bearings The grease sensor FAG GreaseCheck has the following mechanical and physical characteristics see table Description Unit Value Measurement Water 0 to 100 factor Turbidity Oto 100 Ageing 0 to 100 Temperature TE 20 to 100 Analogue output of grease condition mA 4 to 20 Switching output of power supply 24 VDC mA 3 to 150 Working range of sensor SE 5 to 80 Storage temperature range TE 20 to 90 Protection Complete system IP 67 type Sensor head without plug IP 68 Power supply V
6. ble variants Replacement parts are available as stated see table Replacement parts Article number Description 081791828 0000 10 GREASE CHECK COM Sensor head with 800 mm connection cable cable end with plug for evaluation unit Electronic evaluation system in evaluation unit with 5 m connection cable twin paired shielded bare cable end Clamping screw M8 User manual USB adapter and bootloader 081747098 0000 10 GREASE CHECK See GREASE CHECK COM Without USB adapter and bootloader Article number Description 081805845 0000 10 GREASE CHECK OPTIC Sensor head with connection cable 081806124 0000 10 GREASE CHECK JB Electronic evaluation system The grease sensor FAG GreaseCheck is supplied with an electronic evaluation system Prrrnpo user manual GREASE CHECK electronic evaluation system with connection cable sensor head with connection cable internal clamping screw M8 replacement seal 12 TPI234 Schaeffler Technologies Applications Comprehensive monitoring FAG GreaseCheck GQ Arcanol greases 3 FAG CONCEPT 8 FAG SmartCheck Figure 8 Comprehensive monitoring of rolling bearings Installation The grease sensor is generally used in the following areas of application and in particular where rolling bearings with grease lubrication are difficult to access wind energy raw material extraction and processing pulp and paper paper machinery and
7. brings together valuable knowledge relating to mounting and dismounting In individual video sequences the service experts present step by step the points that must be paid close attention for correct mounting lubrication and alignment Scar Tectynetegies AG amp Co KG Germany Dana Privy bant a Back te the introduction a 3 3 E 2 a lt a E 3 5 Contents Condition monitoring of greases in rolling bearings Product overview eensenesssennnssssnnnnnnennnnnnnnnennsnnnnnssnssnnenssssennnnn 4 Features ne A AOAO EEATT 5 Functional principle Design of the sensor head Analysis of the grease condition Greases anne Available variants and replacement parts Ordering examples s siorsssisssssessssossssesssrssenssnsissssissnssseressn Applications egassdesnsosesartegsaceasarersse Comprehensive monitoring eueesssnesssnnerssnenssnnennennnnnnnnnnnnn INStallatiON s c scrcecedscosesacsesstaedentestusaccdassvoeneschandegsscosganeszoe Technical data for FAG GreaseCheCk sssssessrocsrsersrren Services PFOCUCTOVEIVIEW sit co cocntestondeediveveoctead epdecdiadt nates seri s OE 16 MOUNTING rare nn Gesvacesnenedeceueces 17 Lubrication u 2 a a aa 17 Rolling bearing grease ArCanOl s ssssersssrrrersrssrrrersernrrrrnnrt 18 Condition monitoring seeesssssssssssssssseseeeeesesssssssssssssereeeesssss 18 Schaeffler Technologies TPI 234 3 Prod
8. h its trendsetting characteristics to process optimisation and the reduction of life cycle costs In this way you receive the best information on the condition of your machinery Figure 3 Pump 2 FAG SmartCheck Figure 3 FAG SmartCheck application example 18 TPI 234 Schaeffler Technologies Notes Schaeffler Technologies TPI234 19 Notes 20 TPI 234 Schaeffler Technologies MATNR 083993517 0000 TPI 234 GB D 2013092 Printed in Germany by kraus Further information Industrial Aftermarket Products and services for your success www schaeffler com services Schaeffler Technologies AG amp Co KG Postfach 1260 97419 Schweinfurt Germany Georg Sch fer Stra e 30 97421 Schweinfurt Germany Phone 49 2407 9149 66 Fax 49 2407 9149 59 E mail industrial services schaeffler com Internet www schaeffler com services Every care has been taken to ensure the correctness of the information contained in this publication but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler Technologies AG amp Co KG Issued 2013 September This publication or parts thereof may not be reproduced without our permission TPI 234 GB D
9. her plant availability optimised grease quantities and longer lubrication intervals as well as lower maintenance and lubricant costs Products and service for your success reliable versatile and competent Evan after the purchase of a product Schaeffler offers lasting solutions relating to mounting and maintenance With the aid of the diverse portfolio of products and services operating life and performance capability of production plant can be increased and overall costs can be reduced In the Global Technology Network Schaeffler combines its local competence in the regions with the knowledge and innovative strength of its experts worldwide under a single structure Through this combination you will experience optimum support anywhere in the world and thanks to our bundled knowledge innovative and customised solutions of the highest quality This makes it possible to achieve sustainable reductions in the over all costs of your machinery and plant and thus improvements in efficiency and competitiveness With our local centres of competence under the name Schaeffler Technology Center we bring our portfolio of services and our engineering and service expertise directly to your area Details on the Global Technology Network can be found at www schaeffler de gtn Mounting Toolbox mounting made easy http mounting toolbox schaeffler com Figure 1 Mounting Toolbox Foreword The Schaeffler Mounting Toolbox Figure 1
10. is good or poor 100 oy c 80 0001A693 Schaeffler Technologies TPI 234 9 Infrared spectroscopy as a measurement method wavelength Figure 6 Sensor signal and analysis of the grease Condition monitoring of greases in rolling bearings The infrared spectroscopy of grease samples is an established method in laboratory practice that can be used to evaluate not only turbidity but also the development of various bands over time The knowledge gained as a result gives the experts information for assessment of the grease condition Monitoring of the grease is carried out on the basis of characteristic changes in the near infrared spectrum for automatic condition assessment Figure 6 0 01 pm 0 1 wr T u r 0 14 0 12 0 10 0 08 0 06 0 04 0 02 Absorption pm Near infrared Middle and far infrared 10 pm 100 um 1mm 100 Fingerprint area Oxidation band Thickener band Additive bands Transmission WwW oO 0001A720 10 TPI 234 Schaeffler Technologies Greases Figure 7 The basic composition of greases FAG GreaseCheck is suitable for most Arcanol greases from Schaeffler and also following prior calibration for other greases available on the market The optimum lubrication of rolling bearings is a science in itself since greases are highly complex mixtures that must be optimally matched to the specific application condi
11. life of rolling bearings and cause damage In order to achieve the most suitable lubrication Schaeffler can provide specifically designed and tested greases Figure 2 greand ono 1o00 _ Figure 2 Rolling bearing grease for every bearing arrangement 000192B4 Schaeffler Technologies TPI 234 17 Services Rolling bearing grease Arcanol The 17 different greases cover almost all applications They are developed by experienced application engineers and are produced by the best manufacturers in the market Different greases are used depending on the particular application At high operating temperatures the thermally stable special grease Arcanol TEMP120 is used Rolling bearing greases under the name Arcanol are subject to 100 quality inspection The inspection methods at Schaeffler are among the most demanding in the market As a result Arcanol rolling bearing greases fulfil the highest quality requirements Condition monitoring The malfunction free and optimised operation of complex machinery and plant can only be achieved by means of condition based maintenance In many cases Schaeffler uses vibration diagnosis For example FAG SmartCheck is an innovative measuring system for real time monitoring with a patented diagnosis technology Due to the low purchase costs it can be used economically even on smaller subassemblies The compact measuring device can be installed quickly is easy to use and contributes throug
12. tions Greases generally comprise a base oil various thickening agents and additives Figure 7 The mixture sometimes includes solid lubricants In terms of preventive maintenance the grease operating life is the decisive value if it is less than the bearing life In this case bearings are generally relubricated once an operating time of half the grease operating life is reached The major disadvantage of this commonly used method is that the condition of the grease is completely unknown Could it have been used for longer Had it already been changed so significantly by external influences such as temperature or the ingress of water that damage had already occurred in the bearing If the user wanted information on the condition of the grease in the bearing the only option previously available to him was to take a sample and subject it to expensive and time consuming analysis in the laboratory Thickener Additives Anti oxidation Soap or Anti corrosion non soap Anti wear protection 14 30 Een Base oil mineral oil synthetic oil or a mixture of both oils 90 Any solid lubricants 0001A721 Schaeffler Technologies TPI 234 11 Available variants and replacement parts Available variants Replacement parts Ordering examples Scope of delivery Ordering designation Condition monitoring of greases in rolling bearings FAG GreaseCheck is available in a number of variants see table Availa
13. uct overview Condition monitoring of greases in rolling bearings Grease sensor GREASE CHECK 0001A6DA 4 TPI 234 Schaeffler Technologies Features Functional principle Advantages Grease sensor GQ Electronic evaluation system Figure 1 Grease sensor and electronic evaluation system Condition monitoring of greases in rolling bearings FAG GreaseCheck monitors the condition of the grease in the rolling bearing during ongoing operation Grease relubrication is thus oriented to the actual demand replacing relubrication carried out as a function of time Inthe past bearings were regreased as a function of time The grease quantities and lubrication intervals were calculated numerically If the grease sensor is used regreasing can be carried out as a function of condition The grease sensor has a diameter of 5 mm and is inserted in a hole in the housing as close as possible to the rolling bearing The sensor is positioned in the lubricant This grease sensor optically measures the water content turbidity thermal and mechanical wear and the grease temperature directly in the bearing arrangement This information is transferred by cable to the evaluation unit Figure 1 The evaluation unit generates an analogue signal that gives the user rapid and simple information on the condition of the grease The grease sensor facilitates lubrication appropriate to needs lower lubricant costs prevention of unplanned do
14. wntime lower maintenance costs lower equipment costs 00019DD2 Schaeffler Technologies TPI 234 5 Extended advance warning time Machine condition t advance warning time At extended advance warning time DD minutes to days WW weeks MM months yg t grease monitoring Ym t conventional vibration monitoring Lp dB noise measurement YC temperature measurement Changes in grease condition Changes in vibration in the bearing G Machine failure Figure 2 Extended advance warning time by means of FAG GreaseCheck Condition monitoring of greases in rolling bearings Through the use of the grease sensor and the associated electronic evaluation system it is possible to detect changes in the condition of the grease long before damage in the rolling bearing becomes measurable by means of changes in vibration Figure 2 As aresult the replacement of grease can be planned with precision The customer can then decide whether to refresh the grease by means of targeted relubrication or to carry out complete replacement of the grease 100 J De GreaseCheck I I La I I WW MM 0001A691 6 TPI 234 Schaeffler Technologies Design of the sensor head d outside diameter I length of sensor head h penetration depth Housing Electronic system Printed circuit board OLED Reference detector 6 Measurement detector
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