Vibration monitoring system

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Overview
Klüber Lubrication's Online Condition Monitoring provides continuous, real-time insight into lubricant and asset condition to support condition-based maintenance decisions. The programme helps determine when oil changes are actually required, reducing unplanned downtime and optimising total cost of ownership.

Service concept
The service is configurable to customer requirements. Sensors placed at selected measurement points supply continuous data streams. Data processing and interpretation are automated and trigger immediate alerts when predefined thresholds are exceeded. The concept supports predictive maintenance, risk management and Total Productive Maintenance (TPM).

Your benefits with Online Condition Monitoring

• Data-driven oil changes — maintenance based on measured condition rather than fixed intervals
• Instant automated alerts — 24/7 notification on threshold breaches
• Optimised lubrication — avoid over- and under-lubrication to reduce consumption and extend component life
• Real-time transparency — continuous visibility of lubricant and asset status
• Deeper diagnostics — enhanced analysis when combined with Digital LuCA laboratory testing

Intelligent real-time monitoring and expertise
Sensors are installed at strategically selected points to capture key parameters continuously. Secure IoT gateways transmit data to the cloud for centralised processing and evaluation. The system estimates residual oil service life so oil changes are performed precisely when required.

• Vibration and surface temperature measurement (e.g. bearings, gearboxes)
• Oil temperature and viscosity
• Particle wear and water content
• Total Acid Number (TAN) and relative humidity
• Oil cleanliness
• Additional parameters on request

Online Condition Monitoring and Digital LuCA
Real-time sensor data combined with Digital LuCA laboratory analysis provides both continuous monitoring and periodic in-depth fluid diagnostics. Laboratory results complement sensor data with detailed information on contamination, wear, oxidation and ageing for robust predictive maintenance decisions.

At a glance

• Sustainable reduction of total cost of ownership (TCO)
• Improved operational safety through 24/7 monitoring
• Early detection of oil condition changes
• Longer intervals between manual oil samples
• Extended oil service life confirmed by sensor and lab measurements
• Reliable prediction of remaining service life

Technical specifications

• Continuous real-time sensor monitoring of lubricant and asset condition
• Measurable parameters: vibration, surface temperature, oil temperature, viscosity, wear particles, water content, TAN, relative humidity, oil cleanliness
• IoT gateways for secure cloud transmission
• Centralised processing with automated evaluation and alerting
• Automated residual oil life estimation enabling condition-based oil changes
• Integration capability with Digital LuCA laboratory analysis for deeper diagnostics
• Scalable and customisable service programme to meet customer requirements