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CONDITION MONITORING TECHNOLOGIES

Detecting
Lubrication Problems
Using Shock Pulse
Advancements in
technologies now make
it easier to detect
improper lubrication.
James Lundy, CMRP
Ludeca, Inc.

roper lubrication is essential to ensure the longevity of rotating equipment,

yet lubrication-related problems are a source of many maintenance failures. A 1995 TAPPI study indicated that 34.4% of all bearing failures are
due to inadequate lubrication (Fig. 1). This situation, combined with contamination, accounted for 54% of total bearing failures.
In the past, applying condition-monitoring techniques to address lubricationrelated problems has been particularly challenging. Until recently, no technology had
emerged to really take the lead in detecting improper lubrication. However, with
ultrasonic measurements now able to successfully detect energy above 20 kHz, it has
become easier to determine shock pulseand shock pulse is an ideal parameter to
use in pinpointing conditions such as under-lubrication.
Shock pulse
Shock pulse is a measurement of energy in the ultrasonic range commonly referred
to as stress waves. The shock pulse method is designed to use the mounted resonant frequency of the accelerometer to amplify the high frequency, low amplitude
events. There are two types of energy that are measurable in this range.
One is the low amplitude, broadband energy created when the roller element
passes over the normal irregularities in the surface of the bearing race due to the
machining process. This energy will be referred to as the carpet value.
The other type of energy measurable in this range consists of the higher-amplitude shock pulses created when the roller element contacts a defect in the race surface, with up to 1,000 times the intensity of the carpet value. This is referred to as
the max value (Fig. 2).
Shock pulse measurements are amplified by the mounted resonance of the transducer. A band pass filter is applied to the signal to distinguish the shock pulse energy
from other machine vibrations. This remaining energy is then converted to analog
pulses, as shown in Fig. 3, and separated into carpet and max values.
Understanding stress waves
Stress waves that result from metal-to-metal contact are short duration bursts of
energy that travel at the speed of sound. The wavelength of these events is dependent on mass and velocity of the impacting object.
The frequency content within each burst of energy will have a center frequency
with a period of two times the contact time between the impacting objects. Increase
in the mass of the impacting object will result in an increase in the contact time.

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Lubrication Related Failures: 54%

Inadequate Lubrication (34%)

Contamination (19.6%)

Other (18.6%)
Storage & Handling Errors (2.8%)
Installation Errors (17.7%)

Overload (6.9%)

Fig. 1. Breakdown of failure causes as reported at a 1995 TAPPI Engineering Conference

Carpet Level = Bearing Noise

Signal Peaks Above Carpet Noise

dBN
60

dBN
60
Poor

Poor

40

40
Reduced

Reduced

20

20
Good

Good

0
Time

Time
Signal strength shown in logarithmic decibels (dB)
for clarity: 60dB represents a chnge of 1000x.

Fig. 2.

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Increase in the speed of the impacting object

and the contact time decreases. For example a
ball bearing with a two-inch roller element
would create a lower frequency than a bearing
with a one-inch element (Fig. 4).
Detecting stress waves with
shock pulse
To measure the ultrasonic stress waves created
by lubrication deficiencies, we must use a vibration analyzer with shock pulse capabilities. We
must also use an accelerometer designed for use
with shock pulse measurements. If designed
properly, the same accelerometer can be used
for normal vibration measurements, as well as
for shock pulse measurements.
The idea behind shock pulse is to take advantage of the natural frequency or resonance of
the piezo element in the accelerometer to
amplify the low amplitude stress waves created
by the impacts resulting from the breakdown in
the hydrodynamic film of
inadequate or damaged lubrication. This 36 kHz resonance is within the frequency range wherein
the broadband friction noise that is created by
a deficiency in the lubrication film occurs. Its
what makes the shock pulse method so good
for detecting lubrication deficiencies. (Sensor
resonance frequencies may vary depending on
the transducer manufacturer.)
The frictional energy and roller element
impact energy measured by such a specially
constructed sensor is passed through a band
pass filter to distinguish it from interference
created by other machinery vibrations. This
energy is then converted to analog pulses,
which can be processed. The process creates
two shock pulse readings: a carpet value (dBc)
and a max value (dBn).
The carpet value represents the frictional
noise that exists between two metal surfaces
where no bearing damage is present. This
value will increase as lubrication begins to
break down and you approach boundary
lubrication. As boundary lubrication occurs,
more metal particulate is mixed with the lubricating media, contributing to an increase in
the carpet value. Thus, it is an excellent indicator of lubrication condition.
The max value is representative of periodic
high-amplitude bursts of stress waves that are
above the carpet value. These are typically
attributed to the impacts created by metal-tometal contact, due to bearing damage. By
applying peak hold signal processing we can
JANUARY-FEBRUARY 2006

distinguish these peaks from the carpet and

background energy.
It is important to note that due to the
nature of the stress waves being measured by
the shock pulse method, great care must be
taken to ensure a good transmissibility to the
accelerometer. This requires that the surface
be machined down to bare metal, the contact
area between the two surfaces be very clean
and as close to the bearing load zone as possible. It is also important to note that the
mounting technique is critical in ensuring
repeatability of the readings. Stud mounting
is the ideal installation technique, however,
other cam-locking devices will provide proper
contact, are easily removable and can be used
for multiple machine data collection.
Lubrication deficiencies
Lubrication of roller element bearings can be
described as one of five lubrication conditions:
Dry contact 0.00
micron (possible 0.01
micron oxide)
Boundary Lubrication 0.01 micron
Mixed Lubrication 0.01 micron
Elastohydrodynamic Lubrication 1
A.
micron
Hydrodynamic
Lubrication 20 micron
(Elastohydrodynamic
lubrication will generate a low shock
pulse)
A lack of the
proper quantity of
lubrication will iniB.
tiate a series of stress
waves that propagate
away from the point
of initiation at the
speed of sound. These stress waves are a result
of metal-to-metal contact and friction due to
a breakdown in the elastohydrodynamic film
that exists with proper lubrication.
The resulting stress waves can be measured
in the 10 to 40 KHz range, with a center frequency of around 30 kHz. This is a range that
is typically higher in frequency than the typical sonic range, yet lower than the widely used
40 kHz setting for ultrasound measurements.
Sonic range is between 20 Hz and 20 kHz, and

Shock pulse is an
ideal parameter to
use in detecting
conditions such as
under-lubrication.

LUBRICATION & FLUID POWER

Fig. 3A. Unfiltered shck

pulse and vibration.
Fig.3B. Conversion to
analog shock pulse.

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Fig. A

Fig. B.

Undeflected Plate

Undeflected Plate

= C, thus F = C
F

F = Predominant stress wave frequency excited by impact

C = Speed of sound in the component which is impacted
= Wavelength of stress wave generated by impact

Excites Lower
Frequency

Deflected Plate

Fig. 4. Excitation of a
stress wave within a
flat plate due to impact
by a larger (Fig. A)
and a smaller (Fig. B)
spherical object

Excites Higher
Frequency

Deflected Plate

falls mostly within the hearing capability of

the human ear, which ranges from 30 Hz to
18 kHz. The ultrasonic range is from 20 kHz to
100 kHz. Energy measured in this range must
be heterodyned in order to be heard. These
stress waves are typically broadband in nature
and are low amplitude events. This differs
from metal-to-metal impact stress waves,
which tend to be much higher in amplitude
and much more specific in their frequency.
Trending shock pulse
In order to determine when a bearing requires
additional lubrication, one must trend the
shock pulse reading regularly.

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First, we establish a good, known baseline

reading. From this initial baseline we compare
the subsequent readings to determine the optimum time for lubrication. A 10 to 20 db
increase over baseline indicates the need for
additional lubrication. When the additional
lubrication is applied, the shock pulse values can
be re-measured to ensure that the bearing has
been sufficiently lubricated. The values should
decrease as the lubrication enters the bearing. It
may take up to several minutes for these readings to stabilize. Continue applying lubricant in
small amounts, allowing the shock pulse reading
to stabilize after each application, until the readings slightly increase. This slight increase is an
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indication that enough lubrication has

been applied and any additional lubrication would be excessive.
This procedure will allow you to
apply the right amount of lubrication.
With trending and good documentation the proper lubrication intervals
can be determined and adjusted
accordingly.
Points of interest
It is important to note that while the
shock pulse technique relies on measuring the energy created by a deficiency in lubrication, careful trending
can help to detect these deficiencies at
the very earliest stages. This will allow
you the opportunity to correct problems early and reduce their deleterious
effects. This in turn will result in a
reduction in spare parts and maintenance labor cost, reduced downtime,
and lower energy consumption.

The collection, storage and

trending of shock pulse values
will reduce lubrication-related
failures, thereby reducing
downtime and lowering
maintenance costs.
It also is important to note that
when using shock pulse measurements
on variable speed equipment, consideration must be given to the increase in
energy that accompanies an increase in
speed. An excellent analyzer will compensate for this when the proper information is entered, but many analyzers
are not capable of this correction.
During the research for this article,
two surprising observations were made.
The first is that while bearing temperature is a good indicator of over-lubrication, it shows little or no response to
under-lubrication until near failure.
The other is that while under-lubrication can be reliably measured with the
shock pulse approach, there is no consistent indication for over lubrication.
JANUARY-FEBRUARY 2006

Providing the Technology

The shock pulse measurement and trending capability is
a standard feature of the PRUFTECHNIK AGs VIBSCANNER and VIBXPERT condition monitoring vibration
analyzers and supporting software. These products are
available through Ludeca, Inc., of Miami, FL.
Ludeca, Inc. also offers bearing heaters, shims and
laser pulley and roll alignment tools. The companys
29,000-sq ft. Miami headquarters, houses a NUPIC
approved calibration laboratory with NIST certified calibration equipment, ESD protected repair department,
training facilities, warehouse and office space.
According to Ludeca, the company prides itself foremost on its customer-service policy, which includes
technical support and 24-hour turnaround time on
almost all repairs. Loaner components and systems are
available upon request if repairs cannot be performed in
a short time frame. The company also goes to great
lengths to ensure immediate availability of virtually all
parts and systems.
For more information, visit www.ludeca.com

LUBRICATION & FLUID POWER

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Conclusion
The monitoring of shock pulse
energy emitted from roller element
bearings is an excellent method to
detect, trend and determine the
proper correction for lubrication
deficiencies. The bearings may
thereby be provided with the right
amount of lubrication at the proper
time or intervals.
The collection, storage and trending
of shock pulse values will reduce lubrication-related failures thereby reducing downtime and lowering maintenance costs. You will experience an
increase in equipment reliability and
higher production yields. And all this,
after all, is the raison dtre for condition monitoring.
References
1. Bloch, Heinz P., Use Shock Pulse Methods to Monitor Bearings, HYDROCARBON
PROCESSING, December, 2000,
Circle 212 or visit www.MT-freeinfo.com

2. Robinson, James C., Van Voorhis, Brent,

Piety, Kenneth R. and King, Willie, Machinery Surveillance Employing Sonic/Ultrasonic Sensors, application paper by Computational Systems, Inc., May, 2003.

TECHNOLOGY

2006
April 17-20, 2006
Donald E. Stephens Convention
Center
Rosemont (Chicago), IL

FOR INFORMATION ON

FOR INFORMATION ON

EXHIBITING

ATTENDING

CONTACT

GO TO

TOM MADDING

www.MARTSconference.com

847 382 8100 ext. 108

JANUARY-FEBRUARY 2006

Circle 208 or visit www.MT-freeinfo.com

3. Robinson, James C. and Berry, James

E., Description of PeakVue and Illustrations
of its Wide Array of Applications in Fault
Detection and Problem Severity Assessment, Reliability Conference 2001, October
22-25, 2001.

James Lundy is an application engineer

for Ludeca in Miami, FL. He has over 10
years experience in maintenance and
reliability, specializing in vibration
analysis. Lundy is a level 3 Certified
Vibration Analyst and a Certified Maintenance and Reliability Professional
(CMRP). He also is the sitting Reliability
Engineering Standards committee
chair for the Standards Committee
of the Society of Maintenance and
Reliability Professionals (SMRP).
Telephone: (305) 591-8935; e-mail:
james.lundy@ludeca.com
For more information
circle 2 or visit www.LFPfreeinfo.com

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