Air in Oil: A Critical Threat to Heavy-Equipment Machinery

Off-highway and heavy-duty machines operate under extreme conditions where lubricant quality determines efficiency, operating costs, and component lifespan. Air in oil causes cavitation, increased friction, and oxidation, shortening the lifespan of gearboxes and bearings while increasing maintenance costs.

With SBS, operators can eliminate inefficiencies, extend service intervals, and maximize system longevity. Thanks to direct measurement technology, calibration-free long-term monitoring is possible, enabling operators and manufacturers to detect issues early and proactively optimize products and processes to reduce downtime and increase equipment availability.

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Challenges for Operators & Manufacturers

  • Availability & Total Cost of Ownership: Air in oil reduces lubrication efficiency, increases friction, and raises fuel consumption, leading to higher operational costs and reduced machine availability, increasing downtime and decreasing productivity.
  • Maintenance Intervals & Operating Costs: Unplanned downtime and unnecessary oil changes are often based on fixed intervals rather than actual oil condition data, leading to inefficient fleet management, excessive maintenance costs, and wasted resources.
  • Wear & Component Failures: Deposits, cavitation, and oil degradation accelerate wear in gearboxes, bearings, and hydraulic systems. Oil oxidation significantly shortens the lifespan of critical components.

Challenges for Components & Systems

  • Axles, Bearings & Transmissions: Air in oil disrupts lubrication, causing cavitation and increasing friction. Oxidation and deposits raise temperatures and corrosion, leading to premature component failure.
  • Hydraulic Systems & Lubrication Circuits: Foam formation and air bubbles reduce hydraulic fluid compressibility, lowering system efficiency and increasing stress on pumps and oil filters.
  • Cooling, Tank & Pump Systems: Air in oil affects heat dissipation, disrupts even oil distribution in tanks, and causes pressure fluctuations in pump systems, compromising operational safety.
How the SBS Solves Air-in-Oil Challenges in the Off-Highway Industry

How the SBS Solves Air-in-Oil Challenges in the Off-Highway Industry

Air in oil impacts machine performance, lubrication quality, and maintenance costs. Traditional air-in-oil measurement methods fail to provide validated real-time data. SBS enables continuous oil monitoring, detecting air content, oxidation, and lubricant degradation to optimize maintenance cycles and prevent unnecessary downtime.

Instead of reactive maintenance, SBS enables preventive strategies with real-time data for precise root-cause analysis. Operators detect issues early and proactively optimize lubrication strategies, reducing failures and maximizing machine availability.

Equipment Performance & Efficiency

Equipment Performance & Efficiency

SBS detects oxidation and oil aging through precise long-term air-in-oil measurements. This enables data-driven optimization of operating strategies, reducing friction losses and maximizing uptime.

Optimized Maintenance Strategies

Optimized Maintenance Strategies

The SBS monitors air content and lubricant degradation in real time, enabling oil changes based on actual operating conditions. This avoids unnecessary maintenance, extends service intervals, and reduces downtime.

Extended Component Lifespan

Extended Component Lifespan

Cavitation, oxidation, and deposits accelerate wear on critical components. The SBS continuously monitors oil quality, preventing material fatigue and protecting transmissions, bearings, and hydraulic systems from premature failure.

Testing & Implementing SBS in Off-Highway Applications

The SBS technology portfolio includes two complementary test bench setups to analyze air in oil under real-world conditions, either directly in the application or in a controlled laboratory setting.

SBS-ST: Stationary Laboratory Testing

Simulates air bubble formation and cavitation in hydraulic systems and transmissions under real operating conditions.
Ideal for equipment manufacturers and lubricant engineers to validate durable lubrication strategies and oil formulations.

SBS-ME: In-Line Real-Time Measurements

Direct measurement in operating off-highway machines to monitor air entrainment and foaming.
Optimizes maintenance intervals and maximizes machine availability for construction, agriculture, and mining applications.

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Ready to Maximize Machine Availability with the SBS?

The Smart Bubble System supports operators and manufacturers in the agriculture, construction, and mining industries by:

  • Maximizing uptime with optimized lubrication strategies
  • Reducing maintenance costs with root-cause-driven service intervals
  • Extending component lifespan through real-time air-in-oil monitoring
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Find out more about the Smart Bubble System

The Smart Bubble System was developed to optimize fluid management and lubricant strategies along the value chain. Find out what advantages it brings in your specific case.