Strange noises from machinery that is also overheating can be caused by Plummer Block Bearings. These self-contained units take considerable loads and face a lot of wear and tear in an industrial environment.
Bearings Overheating
A high temperature reading is a sign that you’re facing problems with your machinery. You should never be comfortable touching the bearing housing, as this is clearly an issue that needs to be tackled.
Poor lubrication is usually the cause for this. Either there is not enough grease or the grease has hardened and has lost its lubricating properties. Check the lubrication schedule. Many places do routine maintenance and fall behind without even realising it. Also, remember that too much grease, besides bad, can being also be a problem. Excessive lubrication causes churning in the grease, which creates a lot of heat.
Another example is misalignment. When the shafts are misaligned, the bearing works extra hard which leads to friction and heat. You can check the alignment with a straight edge, or for a more precise measurement, a dial indicator. Fixing the problem could mean something as simple as adjusting the mounting bolts. Other times it may require some shimming or the repositioning of some equipment.
Abnormal Noise and Movement
Any unusual noises coming from your equipment can be a very bad sign. Plummer Block Bearings are designed to be very quiet so grinding, squeaking, or knocking sounds require your immediate attention.
Grinding sounds usually mean that some sort of contaminant, like dust or dirt, has gotten into the bearing. This is especially common in outdoor installations or environments with a lot of dust. Check the seals. If they are damaged, or not correctly installed, then it can result in a lot of unwanted contaminant entry.
If there is insufficient lubrication, or if the bearing components are damaged, that can lead to an unwanted squeaking noise. You may notice the squeaking as an intermittent sound, and then it will progress to a constant squeaking. Don’t ignore it, hoping that it will spontaneously get better.
Fishing out a bearing failure can sometimes mean something in your system needs correcting. These things can fail due to an engineering issue and a maintenance issue. Random failures happen occasionally, but patterns indicate systemic issues.
If stress on the system has increased, and the bearing doing the failing has an increased rating, you might simply be asking too much of the system. Run your calculations, and be honest. If the system has to accommodate more, you’ll need to go to the next rating.
Stress concentrations are the stuff of nightmares shorts shafts, causing uneven load distribution. If you have long shafts, add on intermediate supports. If the shafts are halved, use the thicker rod.
Water ingress destroys bearings very quickly. It contaminates lubricant causing corrosion. Check if your seals are good and drainage holes not blocked. In outdoor installations and washdown environments, consider bearing units with better sealing.
Seal Damage and Leakage
Leaking grease shows your seals have failed, which is not just messy. It is only a matter of time before lubricant gets out and contaminants get in. Age and heat cause rubber compounds to crack. Seal damages before they go into service due to improper installation. A rough shaft surface damages seals, regardless of their quality.
Before replacing seals, clean carefully first. Old non-debris in the housings will also damage new seals just as quickly. The correct seal type for your application must be used.
How Regular Monitoring Protects Your Bearings
The issues that arise with Plummer Block Bearings can be overcome with preventative maintenance and proper installation. Note and keep track of your lubrication schedules, temperature readings, and take measurements of vibrations. Records can help show patterns that predict upcoming failures. Teach your maintenance team to identify and understand the key indicators, and the team will spend less time fixing breakdowns.