LUBExpert ON-GUARD - Automatic Bearing Lubrication System

Overview

LUBExpert ON-GUARD is the smartest lubrication system from SDT Ultrasound Solutions. This innovative solution combines automation, precision, reliability, simplicity and safety. The system delivers long, trouble-free operation of rotating equipment by maintaining optimal lubrication through advanced ultrasonic measurement technology.

Reliability through condition-based lubrication

Up to 80% of bearing failures are caused by improper lubrication practices. LUBExpert ON-GUARD removes the guesswork from this critical maintenance task by ultrasonically monitoring friction levels in rotating equipment and applying grease precisely when it's needed.

Rely on data-driven decisions with LUBExpert ON-GUARD. Move away from time-based scheduling toward a maintenance strategy where precision and accuracy come first. This failure-proof approach acts like a "nutritionist" for your machines, preventing problems through a personalised, autonomous, data-driven plan — and in doing so, strengthening the reliability of your operations.

Simple, smart and automatic lubrication

LUBExpert ON-GUARD keeps things simple. Connect to and manage the device from anywhere via its built-in web server, accessible from any operating system, including tablets and smartphones. No client software installation, remote cloud services or extra licences required.

Automation takes centre stage: LUBExpert ON-GUARD performs the complex task of replenishing bearing grease. This not only reduces workload and grease waste, it also keeps the machine running optimally, boosting asset reliability through SDT's precision LUBrain lubrication algorithm. The algorithm automates lubrication, applying grease exactly when needed and in the right quantity.

LUBExpert ON-GUARD's intelligent algorithmic operation further simplifies maintenance tasks by removing the need for training. Ultrasound technology combined with CONMONSense sensors delivers the right amount of grease based on actual bearing condition. The Plug & Play sensor requires no configuration, delivering a seamless user experience.

Safe, eco-friendly and comprehensive operation

LUBExpert ON-GUARD makes safety a priority, carrying out remote grease replenishment to reduce risk in hazardous environments. Beyond safety, the device contributes to a more sustainable future through precise control, preventing both unnecessary depletion and over-supply.

The automatic ultrasonic condition-based lubrication offered by LUBExpert ON-GUARD revolutionises bearing maintenance, delivering significant benefits in two key areas: lubricant consumption and electricity use. By reducing over-lubrication, this method lowers costs and environmental impact. It also extends bearing service life, reducing the need for frequent replacement. In energy terms, condition-based lubrication improves efficiency by reducing friction, which leads to meaningful electricity savings — especially valuable in large-scale operations. In essence, this approach represents a significant step toward smarter, greener maintenance, offering tangible benefits in cost, efficiency and sustainability for modern industry.

The comprehensive options offered by LUBExpert ON-GUARD provide an unprecedented level of flexibility, letting users choose the optimal lubrication strategy for their plant. With various replenishment modes and startup options available through a user-friendly web interface, operators can tailor their approach based on equipment warranty requirements, the LUBrain algorithm, or discharge timing.

Security remains a key focus for LUBExpert ON-GUARD. Your data is stored locally and accessed via MODBUS TCP over the network, reinforcing ownership and control of valuable information. This careful approach ensures a secure environment for critical data, in line with strict data-security protocols.

Equipment

LUBExpert ON-GUARD, equipped with 8 analogue inputs and relay outputs, comes in a steel enclosure available in various sizes to suit user needs.

For a simplified, easy setup, the device ships as a complete kit containing:

• 8 pairs of shielded direct-action sensor cables + lubricator cables, ranging from 5 to 30 metres in length
• 8 true 4-20mA CONMONSense sensors
• 8 lubricators

Once you have all of this, all you need to do is make the power and network connections, connect the sensors and lubricators to the machine, and you're ready to go!

Scope of delivery

Main unit

• Steel enclosure with IP protection
• 8 analogue inputs for sensors
• Relay outputs for controlling lubricators
• Network interface for network connection
• Built-in web server

Sensors and cables

• 8 x CONMONSense 4-20mA sensors
• 8 shielded sensor cables (5-30 metres)
• 8 lubricator connection cables

Lubricators

• 8 automatic lubricators
• Grease reservoir
• Dosing capability

Technical specifications

Specification	Value
System type	Automatic ultrasonic lubrication
Algorithm	LUBrain
Number of channels	8
Input type	Analogue 4-20mA
Output type	Relay
Connectivity	MODBUS TCP, Ethernet
Control interface	Web server (cross-platform)
Sensors	CONMONSense 4-20mA
Cable length	5-30 metres
Enclosure	Steel, IP65
Power	Standard industrial

Advantages

Economic impact

• 30% reduction in grease consumption — precise dosing eliminates over-lubrication
• 50% increase in bearing life — optimal lubrication extends service life
• Reduced equipment downtime — preventing bearing failures
• 6-12 month payback — fast return on investment

Technical advantages

• LUBrain algorithm — intelligent determination of the right moment to lubricate
• Plug & Play — sensors require no configuration
• Web interface — control from any device
• Automation — minimal personnel involvement
• Integration — MODBUS TCP for communication with control systems

Safety and environment

• Remote lubrication — work in hazardous areas without personnel present
• Eco-friendliness — reduced grease consumption and waste
• Energy efficiency — reduced friction saves electricity
• Data security — local storage, network access

Applications

Electric motors

• Critical drive bearings
• Ventilation systems
• Pump units

Industrial equipment

• Conveyor systems
• Gearboxes and transmissions
• Fans and blowers

Specialised equipment

• Compressor stations
• Cooling systems
• Food-industry equipment

Comparison with manual lubrication

Characteristic	Manual lubrication	LUBExpert ON-GUARD
Timing control	Scheduled	Condition-based (LUBrain)
Grease quantity	Approximate	Precise
Over-lubrication risk	High	Minimal
Under-lubrication risk	High	Minimal
Personnel required	Operator	Automatic
Safety	Presence in the area	Remote
Documentation	Manual	Automatic
Grease consumption	Excessive	Optimal

Integration with control systems

MODBUS TCP

LUBExpert ON-GUARD supports the MODBUS TCP protocol for integration with:

• SCADA systems
• CMMS/EAM systems
• PLC controllers
• Monitoring systems

Web interface

• Access from any device (PC, tablet, smartphone)
• No software installation required
• Cross-platform (Windows, macOS, Linux, iOS, Android)
• Secure connection

Operating modes

Lubrication replenishment modes

• By LUBrain algorithm
• By time
• By condition
• Manual mode

Startup options

• Automatic startup
• Scheduled startup
• Condition-based startup
• Manual startup

Conclusion

LUBExpert ON-GUARD represents a turning point in the evolution of lubrication practice, bringing essential elements such as reliability, simplicity and safety together in perfect harmony. Its condition-based reliability makes it an indispensable tool in the arsenal of precision-maintenance strategies. As industries increasingly face the complexities of modern equipment, LUBExpert ON-GUARD is your next trusted companion, dedicated to ensuring bearing longevity and optimal performance of critical assets.