Smart bearings support Industry 5.0

THE CONCEPT of Industry 5.0 emphasises a sustainable, human-centric, and resilient approach to industrial innovation. 

The European Commission (EC)’s report Industry 5.0: Towards a Sustainable, Human-Centric and Resilient European Industry outlines six categories for Industry 5.0. Predictive maintenance will be integral to these initiatives, helping determine the condition of equipment and to estimate when maintenance should be performed. Importantly, this occurs while the machine is in operation, which limits any unnecessary downtime and reduces the probability of unexpected failures.

Smart maintenance

Modern manufacturing relies heavily on bearings. They are used extensively in almost every type of rotating equipment. IIoT-based smart bearings can self-diagnose impending faults and failures, based on data from sensors integrated into the housing of the bearing itself. 

These advanced bearings provide real-time data on temperature, vibration, and load, enabling predictive maintenance and enhancing energy efficiency across various sectors.

Bearings with smart sensor technology can also help drive industries towards more resilient operations and are now being increasingly adopted by industry. Smart bearings can be affixed to technologies to gather various data points.

Applications for smart bearings

The advantages of smart bearings with built-in sensors have seen them gain popularity by being widely used in automotive anti-lock braking systems (ABS) for years.

For example, SKF manufactures groove ball bearings with integrated sensors that are capable of measuring various factors such as speed, acceleration, number of revolutions, and direction of rotation. These bearings are utilised in applications including electric motors, gearboxes, linear actuators, and shafts, where precise control and monitoring are essential.

The bearings can be integrated with a second sensor to determine the direction of rotation, allowing for comprehensive monitoring of machinery movements. Furthermore, the bearings are designed to withstand a wide temperature range (minus 40 to plus 120 degrees Celsius), making them suitable for industrial environments. This data aligns with the scenario described, showcasing the practical application of smart bearings in an automated manufacturing facility for continuous supervision and optimised equipment operation.

Smart bearings with built-in technology also have potential uses in motors, pumps, and fans, which are essential parts of many machines. For example, if dirt contaminates a fan's blades, it causes vibration. Detecting these vibrations early can help adjust the system quickly, reducing the risk of equipment failure and costly repairs. 

Furthermore, smart bearings can be part of the "data transmission, storage, and analysis technologies" outlined in the EC’s report. Bearings with integrated sensors can send signals to an external monitoring unit. This unit records performance data and predicts how much longer the component will last. Operators can then receive alerts in real-time wirelessly, removing the need to be on the shop floor constantly.

As the EC’s vision for Industry 5.0 takes shape, integrating sustainability, human-centric values, and resilience into industrial practices, sensor-equipped smart bearings will emerge as a pivotal technology.

Chris Johnson is managing director of SMB Bearings 

For more information: 

www.smbbearings.com

Tel: +44 (0) 1993 842 555