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LUBRICANTS


ANALYSIS METHODS


INDUCTIVE PARTICLE COUNTER (SENSOR)


The system’s oil monitor works by utilising an inductive particle counter (sensor), which is able to distinguish between ferrous and non-ferrous metal particles that are present in the lubricating oil. On a typical industrial gearbox application, the particle counter or sensor is installed in the oil flow, directly before the oil filter, or as a separate circuit. The sensor operates on the principle that any wear to a component such as a bearing or gear tooth will result in small metal particles being rubbed off into the oil, often several months prior to an actual failure.


The sensor provides information on the number of particulates present in the oil, and then classifies these according to their physical size. Analysing the oil in this way enables damage and wear to the gears to be detected much earlier, even in planetary gearboxes, such as those used on wind turbines.


VIBRATION MONITORING In addition to oil analysis, the FAG Wear Debris Monitor also monitors the vibration behaviour of the machine and its components, including rolling bearings and gear wheels. By installing sensors on the machine or gearbox that needs to be monitored, the new system detects changes in the operating behaviour, indicating early signs of damage. This enables the plant to start suitable repair work or plan some scheduled maintenance in order to prevent failure of the machine, resulting in costly production downtime.


UNIQUE COMBINATION This unique combination of oil and vibration monitoring provided in a single online condition monitoring system, means that users receive earlier warning signs of gear damage than if vibration monitoring is used on its own, or vice versa.


After any damage is detected, professional damage analysis is then required in order to determine the possible causes. The results of this work then lead to recommendations or remedial action that will prevent similar damage in the future.


viewing of digital photos and video. By using a special interface, the FAG Wear Debris Monitor can be easily integrated with other online condition monitoring systems from Schaeffler, including the FAG DTECT WiPro s and FAG ProCheck systems. These condition monitoring systems can be adapted or retrofitted to suit any customer requirements.


“The combined use of FAG oil monitoring products, vibration monitoring products and services from Schaeffler provides an efficient, cost-effective method of improving the protection of oil-lubricated gears. By detecting damage early, and by using the wide variety of analysis methods,


www.windenergynetwork.co.uk 95


the operational reliability of gears can be improved significantly, leading to similar improvements in productivity,” commented Christian Meindl, Product Manager Oil Monitoring Products at Schaeffler Industrial Aftermarket (IAM).


The Schaeffler Group www.schaeffler.co.uk


Schaeffler UK is able to provide a wide variety of analysis methods to assist the customer. Endoscopy, for example, is used to determine the full extent or severity of any damage. Video endoscopes enable the internal components of a machine to be inspected, allowing the user to make a diagnosis of the damage based on the


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