Online condition monitoring - Lastfordonsgruppen

We produce fluid power solutions Oil Condition Monitoring / Page 1 Lars Fredenwall

Online condition monitoring


Motivation for Condition Monitoring Failure causes by the example of a bearing

Lack of lubricant

15%

aged lubricant

20%

liquid contaminents

5%

solid contaminents

20%

unsuitable lubricant

20%

other

20%

Source: Prof. Gold: IME RWTH-Aachen


Quelle: Prof. Gold: IME RWTH-Aachen

Motivation for Condition Monitoring Failure causes by the example of a bearing

Lack of lubricant

15%

aged lubricant

20%

liquid contaminents

5%

solid contaminents

20%

unsuitable lubricant

20%

other

20%

80% of the failure causes can be detected

by the condition of the lubricant!

Condition monitoring of the lubricant is

of crucial importance to reduce downtime!


CME Product portfolio Overview


functionality

price

LubCos H2O

Humidity sensor

LubCos Level

Oil condition and level

LubCos Vis+

Viscosity sensor

LubCos H2O+

Oil condition

LubCos Products Oil condition sensors


Oil Temperature in [°C]

20

rel.

Oil

Hu

mid

ity

[%]

A

B

C

40 60 80

abs. Water Contamination in [ppm]

100 A B C

0

25

50

75

Re

l. O

il H

um

idit

y [%

]

100 500 1000 1500

Constant

Absolute Water Contamination

Constant

Temperature

LubCos H2O/H2Oplus/Level Relative Humidity in different Oil Types

ca. 200 ppm 423 ppm 2871 ppm 10441 ppm

(0,02%) (1,04%)


Multi-Disk Brake LubCos H2Oplus II temperature compensated rel. permittivity

2,05

2,15

2,25

2,35

0 1000 2000 3000 4000 5000 Operating Time in h

rel.

perm

itti

vit

y

left right

Rel. Permittivity Measurement Summary


Multi-Disk Brake LubCos H2Oplus II

temperature compensated rel. permittivity

1000

10000

100000

1000000

0 1000 2000 3000 4000 5000

Operating Time in h

Co

nd

uct

ivit

y in

pS

/m

left right

Conductivity Measurement Aging Correlation

Engrenage 3470 ISO VG 220 Gear Oil

Low conductivity at start High conductivity at start

AgriTrans Plus CVT80W

Trend = Aging of

basis oil!

Trend = Depletion

of additives!

Medium conductivity at start

Trend = Aging

of basis oil +

overlaid additive

depletion!


Parameters and their Information Temperature Compensation and Detection of Oil Mixture

2,10

2,11

2,12

2,13

2,14

2,15

2,16

2,17

2,18

2,19

2,20

0 1000 2000 3000 4000 5000

Betriebsstunden [h]

rel. D

iele

ktr

izitäts

konsta

nte

[-]

0

1000

2000

3000

4000

5000

6000

7000

0 1000 2000 3000 4000 5000

Betriebsstunden [h]Leitfä

hig

keit [

pS

/m]

P

P40

C

C40

operating hours [h] operating hours [h]

rel. p

erm

ittivity [-]

co

nd

uctivity [p

S/m

]

Oil refresh detected


Automated Oil Condition Monitoring Calculation schema for Remaining-Useful-Lifetime (RUL)

plausibility check

plausibility check

plausibility check

plausibility check

Thermische Lastfaktoren fB

0

0,02

0,04

0,06

0,08

0,1

0,12

0,14

0,16

0,18

0,2

Antwerpen Marseille VC23 Marseille VC24 Marseille VC25 Marseille VC26

Hydraulik Bremse 1 Bremse 2

stored data

thermal load

factor/ Ref. RUL

LTG calculation

RUL calculation

data aggregation &

plausibility check

temperature

P40

C40

timer

RUL

1

1 1 machine specific parameterisation

LTG = long term gradient

RUL = remaining useful lifetime


Oil life cycle h

Operation time [h]

Oila

gin

g

RU

L

0 h

Oil change

Reset:

Learn fresh

oil values RUL determined by

temperature load

RUL

RUL determined by

parameter shift

Start

Oil life cycle h

Reset:

Learn fresh

oil values

RUL

ALARM RUL

Warning RUL

Automated Oil Condition Monitoring Oil lifecycle view


Available Sensors Multi Parameter Sensor LubCos Visplus

power supply 9..33V

4000 datasets memory

RS232 and CANopen

2 analog outputs 4...20mA

protection class IP 67

IDC

SAW

temperature Parameter

viscosity and V-T-gradient

rel. permittivity

temperature

transducers

derived information

• oil deterioration

• contamination

• right type of oil


0

10

20

30

40

50

60

70

80

Con

dat D

46

Con

dat D

68

Shell Ase

ol T

erra

46

Avia

Synto

fluid

Shell Iru

s DU 4

6

Shell STX 3

2

Shell Tel

lus

VG 4

6

Shell Tel

lus

VG 6

8vi

scosi

ty [

mm

²/s]

SAW-viscosity at 40°C

Ubbelohde viscosity at 40°C

SAW-viscosity at 85°C

Ubbelohde viscosity at 85°C

0

10

20

30

40

50

60

70

80

90

100

20 40 60 80 100

temperature [°C]

visc

osi

ty [

mm

²/s]

SAW-Sensor

Ubbelhode viscosimeter

type of oil:

Condat D46

Application example SAW-Viscosity SAW-viscosity sensor compared to viscosimeter


Application Example - Press Viscosity measurement

20

40

60

80

100

120

140

160

180

200

30 230 430 630 830

Operating hours [h]

Vis

co

sit

y [

mm

²/s

]

0

10

20

30

40

50

60

Te

mp

era

ture

[°C

]

V

V@40°C

Temp.




Available Sensors Particle Monitor OPCom II


Accuracy

Price

Particle Monitor

Contamination sensor

Portable Oil Lab

Oil analyze unit

OPCount

Particle counter

FerroS

Wear sensor

OPCom Products Contamination and wear monitoring


Sensor parameter:

Measurement Metallic wear

Interfaces 4-20mA,RS232,

CANopen, J1939

Power supply 9..33V

Protection class IP 67

Connection M12x1, 8pins; G1“

Continuous monitoring of ferromagnetic wear particles

Automated condition monitoring, no more manual

inspection needed

Robust against disturbances (air, water, vibration, …)

Ideal to monitor gearboxes and heavy machinery

OPCom FerroS Ferromagnetic wear sensor


OPCom FerroS Ferromagnetic wear sensor


Output signal

12

16

20

8

24

cu

rre

nt [m

A],

co

llecte

d d

eb

ris

4

time

0

Particle counting OPCom FerroS

Step height = particle size

Shorter time = rising debris concentration


OPCOM II Particle monitor

Sensor parameter:

Particle classes 4, 6, 14, 21 µm(c)

Standards ISO4406

SAE AS 4059

NAS 1638, GOST 17216

Temperature -10°C...80°C

420 bar max. pressure

50...400 ml/min flow

Voltage 9…33V

3.000 datasets memory

4-20mA , RS232, CANopen, SAE, J1939 interface

Digital In & output

Protection class IP 67


OPCom Portable Oil Lab Oil dignosis system

Particle classes 4, 6, 14, 21 µm(c)

Standards ISO4406

SAE AS 4059

Temperature -10°C...80°C

Relative humidity 0...100%

Integrated pump and printer

Powerful battery

320 bar pressure measurement



OPCount Particle counter for laboratory and service

Sensor parameter:

Particle classes

2, 5, 10, 15, 20, 25, 50, 100µm

4, 6, 10, 14, 21, 25, 38, 70µm

Standards

ISO 4406 NAS 1638 SAE AS 4059 GJB 420A

GOST 17216 EI-IP 577 DEF-STAN 91-91

High accuracy

Sampling via integrated pump or pressure line (420bar)

Intuitive handling and operation with touch display




LubMon Software

Data processing and

configuration

LubMon Visu

Display and memory unit

LubMon Connect

Remote-Gateway

Functionality

Price

LubMon Products Data display and processing


LubMon PClight and LubMon Config Measurement and configuration software

Parameter:

Interface RS232, USB,

Ethernet

Functionality Graphical display

Data management

Sensor configuration

For Windows XP/Vista/Windows 7

Plug&Play with all AH Sensors

Download for free at http://www.argo-hytos.com


LubMon Visu Display and storage unit

Parameter:

Inputs 2x RS232

2x 4-20mA

Outputs 3x Digital

Printer

USB

SD-Card

Ethernet (optional)

9..36 Volt


Plug&Play with all AH sensors


Condition indicator Smartphone

Oil condition sensors

Gateway PLC

Online Condition Monitoring Concept for installation and data transmission

CANopen / 4-20mA

Live Demonstration:

argohytos.remoteportal.de

E-mail

www

SMS

E-mail

www

GSM

Internet

Database

cable

Machine display

http://argohytos.remoteportal.de/

https://argohytos.remoteportal.de/


Benefits:

alarm limit

Continuous monitoring of

machine condition

Local and global display of

data possible

Customizable data display

and export functions

Easy setup of limits and

monitoring functions

Automated messaging

when set limits are reached

Application Example – Test Bench Monitoring and automated alarm handling


Online Condition Monitoring Warnings and alarms


Service and maintenance How and when?

1 Wait until crash

2 Fixed service intervals

3 Service when needed


Applications


Application

Straddle carrier / container handler

Customer

Noell/Terex

CME Products

LubCos H2O+

Benefit

Monitoring of oil condition in Hydraulics and brakes.

Monitoring of oil condition


0

20

40

60

80

100

0 1000 2000 3000 4000

time [h]

hum

idity [

%]

unit 1

unit 2

unit 3

unit 4

0

200

400

600

800

1000

1200

0 1000 2000 3000 4000

time [h]

co

nd

ictivity [

pS

/m]

unit 1

unit 2

unit 3

unit 4

upper limit

2,00

2,05

2,10

2,15

2,20

0 1000 2000 3000 4000

time [h]

perm

ittivity [

-]

unit 1

unit 2

unit 3

unit 4

upper/lower limit

0

2000

4000

6000

8000

10000

0 1000 2000 3000 4000

time [h]

RU

L [

h]

unit 1

unit 2

unit 3

unit 4

Results:

• The measurement in all

monitored machines are

comparable

• Humidity: The value at

startup and during

operation is very low

• Conductivity & Permittivity:

The values are steadily

increasing.

• Oil aging: The former oil

change interval of 4000h

has been extended to a

value of about 6000h

Service planed

Service warning

upper/lower limit

humidity warning

humidity alarm

upper limit

Monitoring of oil condition in mobile application


0

20

40

60

80

100

0 1000 2000 3000 4000 5000

Zeit in h

Ag

ing

Pro

gre

ss [

%]

0

20

40

60

80

100

Time

Agin

g p

rocess [

%]

left brake

right brake

linearization

Results:

• The aging progress in the

two independent brake

circuits develops similar

• The former oil change

interval of 2000h has been

extended to about 5000h.

The results were confirmed

by an independent

laboratory.

Monitoring of oil aging in brake circuit


08.05.2007

refresh: Symrol CM46

quantity: 3 liters

10.08.2007


quantity: 3 liters

22.09.2008

refresh: Renolin B15

quantity: ?

0

5000

10000

15000

20000

25000

30000

24.03.06 28.04.07 01.06.08 06.07.09 10.08.10

time [dd.mm.yy]

co

nd

uctivity [p

S/m

]

s s

28.09.2007

oil change: Renolin B15

quantity: 20 liters

18.12.2009


quantity: 20 liters

2,075

2,100

2,125

2,150

2,175

2,200

24.03.06 28.04.07 01.06.08 06.07.09 10.08.10

time [dd.mm.yy]

rela

tive

pe

rmittivity [

-]

08.05.2007


quantity: 3 liters

10.08.2007


quantity: 3 liters

28.09.2007


quantity: 20 liters

22.09.2008

refresh: Renolin B15

quantity: ?

18.12.2009


quantity: 20 liters

s s

max. system

volumen :

25 liters

Monitoring of oil condition in milling machine


We produce fluid power solutions

www.argo-hytos.com

Online condition monitoring - Lastfordonsgruppen

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