Schaeffler has developed a DuraSense system that automatically lubricates linear recirculating ball bearings and rail assemblies. The system uses built-in lubrication and vibration sensors to automatically lubricate related components without manual lubrication, and provides the required precise lubrication for individual linear axes based on load and other factors, up to 6 brackets on one axis .
The DuraSense system is reported to prevent under-lubrication and excessive lubrication, extending machine life and reducing failure rates. It also detects relubrication system failures such as hose leaks or grease clogging. The DuraSense system eliminates the need for pressure sensors for complex monitoring, such as pressure sensors used in centralized lubrication systems. Even interconnected systems protect it without costly downtime.
If the monorail guidance system moves only a short distance, the system will reduce the frequency of the lubrication pulse; if the load is heavy, the frequency will increase. If the bracket is contaminated by foreign matter or fluid, the built-in vibration sensor detects this through solid sound transmission and triggers a lubrication pulse while removing contaminants and lubricants.
Schaeffler said that without this function, the guiding system will continue to operate with contaminants on the rolling contact surface until the next planned lubrication, which may cause serious damage to the system.
The DuraSense system also helps determine the remaining life of linear recirculating balls, roller bearings and rail assemblies. When these components are operated for a long time, material fatigue may occur near the surface. The measurement system detects this and increases the frequency of the relubrication pulse. The shaft will run smoothly and maintain product quality for a longer period of time.
Even if the linear guidance system continues to operate in this situation, the shorter intervals between the lubrication pulses can be sensed and used to predict the remaining useful life of the navigation system. This calculation, which will be provided as a digital service in the future, can be scheduled for maintenance based on actual operational data and system conditions.
In addition to eliminating the need for manual lubrication, it means that machine builders will no longer be limited by the limited control options offered by centralized lubrication systems. The system is suitable for Schaeffler's KUVE and KUSE 4-row and 6-row linear recirculating ball bearing and guide assemblies and their RUE linear recirculating roller bearings and guide assemblies. The sensor can be placed on either side of the bracket or on the left or right side of the end piece.
Schaeffler's linear recirculating roller bearings and guide assemblies were first introduced in 2017 for automatic lubrication and are now further extended to ball bearing systems.
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