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Proactive maintenance and correct operating practices are key to preventing bearing wear and failure. In this chapter, we present a comprehensive set of preventive measures — from design selection to daily maintenance — that can significantly extend bearing service life in harsh industrial and mining environments.
Every application has unique operational conditions. Choosing the appropriate bearing type and material is the first line of defense.
Best Practices:
For mining in Chile or Peru: Use tapered roller bearings with high load capacity
For high-moisture areas in Brazil: Use stainless steel or sealed bearings
Consider ceramic or hybrid bearings in electrically active environments
Tip: Collaborate with your supplier to analyze actual working loads, speeds, and environmental conditions before selection.
Lubrication ensures smooth operation and minimizes wear from friction and heat.
Key Recommendations:
Choose the correct lubricant (e.g., EP grease for shock loads, synthetic oil for high temps)
Maintain correct lubrication intervals based on working hours and environment
Use automatic lubricators where manual greasing is difficult or unsafe
Important: In dusty environments like mines, consider lubricants with strong sealing additives to prevent particle intrusion.
Improper installation is one of the most common causes of early bearing failure.
Installation Guidelines:
Preheat inner rings before mounting using induction heaters
Avoid hammering or using excessive force
Use precision alignment tools to ensure proper shaft and housing positioning
Follow manufacturer torque and clearance recommendations
Contamination often starts during installation and assembly, especially in field environments.
Preventive Steps:
Clean all tools and workspaces
Store bearings in sealed packages until use
Wear gloves to avoid introducing sweat or particles
Use sealed storage containers for spare parts in damp climates
Real-time monitoring helps identify early warning signs of wear or damage.
What to Monitor:
Vibration levels using accelerometers
Bearing temperature with infrared sensors
Shaft alignment and RPM
Lubricant condition (e.g., water content, viscosity)
Use Predictive Maintenance (PdM):
Employ condition monitoring systems to trigger maintenance based on real-time data, especially in high-value equipment used in mining or metallurgy.
Shock loading shortens bearing life dramatically.
Prevention Tactics:
Use soft-start motors and clutches to reduce sudden torque
Design machine frames and shafts to distribute load evenly
Choose bearings with a higher dynamic load rating for demanding applications
Moisture is one of the most destructive contaminants in bearing systems.
Protection Tips:
Use double-lip or labyrinth seals for wet conditions
Install desiccant breathers in storage or idle equipment
Apply anti-rust coatings during long-term storage or export shipping
When operating in extreme conditions, consider using bearings with specialized surface technologies.
Examples:
Black oxide coatings for corrosion resistance
Chrome-plated raceways for better wear resistance
Nano-polished surfaces to reduce friction and noise
Conclusion:
A well-rounded maintenance strategy — beginning with proper selection, supported by clean installation, reliable lubrication, and real-time monitoring — dramatically reduces the risk of bearing wear. For businesses operating in challenging environments like Latin American mines or European heavy machinery sectors, proactive care translates directly into uptime, cost savings, and operational safety.
Early detection of bearing wear is essential to prevent unexpected machine failure, reduce downtime, and lower maintenance costs. Recognizing the signs of bearing wear at its initial stage allows timely intervention and prolongs bearing service life. Below are the key methods and indicators for early identification of bearing wear.
Look for surface abnormalities on bearing rings and rolling elements such as discoloration, pitting, corrosion spots, or micro-cracks.
Check for lubricant contamination, which often signals seal failure and accelerated wear.
Inspect for deformation or scoring marks on the raceways and cage components.
Bearings in good condition typically produce smooth, low noise during operation. An increase in noise level or abnormal sounds such as grinding, clicking, or squealing indicate wear.
Use vibration analyzers to monitor changes in vibration amplitude and frequency. Early wear often manifests as increased vibration at characteristic bearing defect frequencies.
Trends in vibration data over time provide reliable early warning before visible damage occurs.
Bearing temperature rises abnormally when wear develops due to increased friction and metal-to-metal contact.
Early-stage wear often causes a gradual increase in operating temperature beyond normal limits.
Continuous temperature monitoring and comparing with baseline values help detect abnormal heat generation timely.
Analyze lubricant for contaminants such as metal particles, water, or debris, which accelerate bearing wear.
Changes in lubricant viscosity or appearance (darkening, thickening) indicate deteriorated lubrication.
Regular oil analysis helps detect wear particles and prevents further damage.
Increased power consumption or load fluctuations in equipment can indicate bearing wear.
Reduced rotational accuracy, increased shaft runout, or unexpected operational resistance are mechanical signs.
Monitoring equipment efficiency and operational parameters supports early fault diagnosis.
Early-stage bearing wear can be effectively identified by combining visual inspections, vibration and noise monitoring, temperature control, lubricant analysis, and equipment performance evaluation. Implementing a comprehensive condition monitoring program is key to extending bearing life and reducing unexpected failures.
