Lubrication analysis
Sensor monitoring of lubricated systems
To assess the condition of lubricated systems, DEKRA has a tribological laboratory in Utrecht and specialists who can determine the degree of wear on components. They do this by analyzing a sample of the lubricant from a system. An excessive amount of wear particles in the lubricant indicates that a component may need to be overhauled or replaced. The maintenance strategy of a system is often based on the results of periodic analyses performed in the lab. Recent technological developments in the field of sensors offer new possibilities: instead of periodically taking and analysing a lubricant sample, built-in sensors can constantly collect and provide current data about the condition of a system. DEKRA experts talk about the advantages and application of this technique.
Lab analysis
Lubricated components in rail vehicles, wind turbines, hydraulic systems in infrastructural installations (such as lift bridges) and combustion engines are some examples of technology in which condition monitoring plays a key role. These components must continuously perform optimally; a train must run according to schedule and a lift bridge must open and close at the right time to allow traffic to pass. Regular research is required to guarantee safety and continuity. Joris Manders, Tribology Expert at DEKRA explains: “By periodically examining a lubricant sample from a system, we can determine in good time, based on trend analysis, when overhaul or replacement is necessary. This prevents sudden outages. "
The advantage of sensor monitoring
“The disadvantage of periodic analyses is that they are snapshots,” says David van Beukering, Tribology Expert. “Since the technology makes it possible to continuously monitor a system with the aid of sensors, we are researching its application. The technology is now so advanced that sensor monitoring can be of added value in various areas. Consider, for example, analysing samples from hard-to-reach systems, such as at the top of a wind turbine. Collecting a sample is then a costly, time-consuming and difficult job. Or consider systems with an increased risk of failure, where constant monitoring makes it possible to intervene more quickly in the event of an imminent defect. A built-in sensor offers a solution in many places. ”
Implementation process for sensor monitoring
Before you can determine whether monitoring with a sensor is possible, you must have sufficient knowledge of the system, the degradation behavior and the environmental factors that influence it. “We have a lot of experience with this at our DEKRA office in Utrecht,” says Manders. “After the system inventory, the next step is to determine parameters. We define the quantities to be measured and determine the measuring range and the required accuracy of the sensor.
The next step is to preselect sensors. Van Beukering: “We select sensors that could be suitable. That suitability must then be validated. In the lab, we adjust the sensor and determine the alarm limits specific to a component. We then test whether the selected sensor actually displays the correct measurements in practice under the circumstances in which it should do so. The sensor must be able to withstand environmental factors and always provide reliable measurements, even if it is subject to vibrations or shocks, for example. If the sensor turns out to be suitable after this check, we will start with the implementation. ”
Automated data analyses
When one or more sensors are installed and put into use, the process of data collection and analysis begins. DEKRA also advises on this. Manders: “We are already able to automate data analysis for specific applications, such as monitoring suspicious systems or validating changes in the system. Deviations are immediately identified, which minimizes the risk of consequential damage. ” For the time being, sensor monitoring is complementary to lab research. “Sampling with lab analysis serves as a second line condition monitoring to complete the picture of the lubricant and the system and to identify deviations in time. In addition, we also monitor the sensor to ensure that it continues to do its job properly. ”
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