New sensor for online condition monitoring of grease in bearings

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New sensor for online condition monitoring of grease in bearingsSchaeffler is launching a new sensor for online condition monitoring of grease in rolling bearings, particularly in critical plant and machinery located in difficult-to-access areas, such as wind turbines and automated assembly lines.

Developed by The Schaeffler Group in conjunction with Freudenberg Dichtungs und Schwingungstechnik GmbH & Co KG and lubricant specialist Klueber Lubrication, the new grease sensor incorporates an innovative electronic evaluation system that enables the condition of the grease to be monitored while the bearings are operating. The sensor is positioned directly in the rolling bearing immersed in the grease.

This new sensor is described as a significant breakthrough because the schedule for replacing rolling bearing grease can now be scheduled precisely. Any changes in the condition of the grease are detected early, long before any damage can be caused to the bearings.

Grease life

In preventive maintenance regimes, the operating life of the grease is critical, particularly if the life of the grease is less than the expected life of the bearing. In this case, the bearings would normally be relubricated halfway through the grease operating life. The disadvantage here is that the grease is replaced without knowing anything about its actual condition. For example, it may have been possible to continue using the grease for longer without affecting the performance of the bearing. Conversely, perhaps damage has already occurred to the bearing due to ingress of water or high temperatures, so the grease should have been replaced earlier.

Up to now, users could only gather information about the condition of the grease inside a bearing by taking a sample and then conducting costly, time-consuming laboratory analysis. However, the new grease sensor enables grease to be replaced according to the actual operating requirements of the bearing and not according to any predefined time intervals. This is referred to as 'demand-based' rather than 'time-based' relubrication. The result is a reduction in the cost of lubricants, replacement parts and maintenance, while also benefiting the environment in terms of the volume of lubricant used. In addition, operational downtime of plant and machinery will be reduced, and process efficiencies and machine utilisation will also improve.

How the grease sensor works

The grease sensor, which has a diameter of just 5mm and a length of 40mm, is able to detect four parameters of the grease: water content, cloudiness (opacity), wear (thermal or mechanical) and temperature. From these parameters, the sensor's electronic evaluation system utilises complex software algorithms to generate an analogue signal (4-20mA) that indicates the condition of the grease. By setting alarm thresholds (limit values), digital signal outputs can also be generated, indicating whether the grease quality is 'poor' or 'good'. The user can decide at which point in the condition of the grease (from 100 per cent for as-new, to a theoretical 0 per cent for an unusable grease) relubrication or grease replacement should be carried out.

The sensor operates by using the optical, near-infrared reflection principle. This method – developed in conjunction with the Fraunhofer Institut for Electronic Nano Systems (ENAS) in Germany – is based on an infrared process used by laboratories to measure the quality of grease, but has been adapted for online measurements in rolling bearings.


However, developing the grease sensor required not only the design of the sensor, but also methods for evaluating the measurements. The method involves the rotationally symmetrical irradiation of the grease at an angle of 45 degrees using certain wavelengths within the infrared spectrum by the sensor. The sensor head is embedded directly in the lubricant during this procedure. The reflected light is measured perpendicular to the grease, which enables any shadow effects or surface anomalies to be excluded. The reflected light is then evaluated in terms of the quality of the grease.

In terms of sensor set-up, the optimum measurement point will vary depending on the application. Experienced application engineers at Schaeffler will provide advice and guidance to customers and will specify where the sensor should be positioned for each specific application.

Cables are used to provide power to the sensor and to transmit signals from the sensor to the electronic evaluation system. However, if required, a wireless system can be provided.

Schaeffler, Freudenberg and Kluber have validated the measurement method for around 95 per cent of greases currently available on the market. Online monitoring of the condition of the grease enables users to draw conclusions and to react quickly to any changes that may suddenly occur. It also enables the bearing design and position to be optimised.

A further sensor is currently being developed for integration in rolling bearing seals.

For more information on the rolling bearing grease sensor, call the Schaeffler UK Marketing Department on +44 (0)121 313 5870 or email .

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