Online Condition Monitoring: Always in control

With real-time monitoring always one step ahead: How well are your assets performing – and when is an oil change genuinely necessary? How can you maximise uptime whilst reducing total cost of ownership? Those who can answer these questions with confidence retain full control over their production: bearings, chains and gearboxes run longer, unplanned downtime is avoided, and both efficiency and profitability improve measurably. To support plant managers and maintenance engineers in precisely this challenge, Klüber Lubrication developed the Online Condition Monitoring programme. 

This service programme monitors the condition of your assets in real time and can be tailored precisely to your individual requirements. You gain immediate access to up-to-date information on the status of your machinery, lubricants and lubrication systems. Sensors deliver continuous real-time data – analysis and interpretation are fully automated, with no manual intervention required. Should critical threshold values be exceeded, you receive an instant alert. This significantly enhances operational safety and lays the foundation for highly efficient maintenance processes – fully aligned with the principles of predictive maintenance, risk management and Total Productive Maintenance (TPM). 

Intelligent Real-Time Monitoring and Klüber Expertise 

Which sensor solution best suits your requirements? Our experts are on hand to advise you and identify the right approach together. Sensors are then installed at strategically selected measurement points, continuously capturing key parameters: 

• Vibration and surface temperature measurement, for example on bearings and gearboxes 
• Oil temperature and viscosity 
• Wear particles and water content 
• Total Acid Number (TAN) and relative humidity 
• Oil cleanliness 
• Further parameters available on request 

IoT gateways transmit measurement data securely to the cloud, where it is centrally processed and evaluated. Thanks to our expertise, we are able to determine the residual service life, particularly of oils. The result: oil changes are carried out precisely when they are actually required – neither too early nor too late. 

This approach to Predictive Maintenance offers decisive advantages: rather than waiting for visible signs of component wear, the real-time condition of the lubricant itself tells you how effectively your tribological system is performing. Maintenance intervals can be extended and asset service life prolonged. A further benefit: precise sensor data helps you avoid both over- and under-lubrication – reducing costs and cutting lubricant consumption considerably.