Improper lubrication is a leading cause of bearing failure, often due to incorrect grease quantity or frequency rather than lubricant type. A condition-based lubrication approach using ultrasound enables precise determination of optimal grease levels by monitoring friction. This method replaces fixed replenishment schedules with real-time adjustments tailored to each bearing’s condition. Case study results show that traditional methods led to widespread mis-lubrication, with the majority of bearings over-greased and others under-lubricated. Ultrasound-guided lubrication improves reliability, reduces grease consumption, enhances data tracking, and supports optimization of maintenance programs, delivering both performance and cost benefits.

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