How to avoid machinery wear with OilWear

OilWear is a sensor that is capable of revealing, in real time, the quantity and type of wear that is produced in a critical machine. It makes it possible to distinguish whether the appearance of particles is caused by a phenomenon of adhesive wear, abrasive wear, fatigue or corrosion; this allows decisions to be taken with a better information base and avoids machinery wear by anticipating unplanned down time.

The degradation of critical machinery comes with high financial costs. Not only the replacement of the worn out parts but also the down time, whether planned or unplanned, of the system while these replacements are made all go to make the processes more expensive. Active measurement of the patterns of wear of the machine, which is what OilWear offers but which cannot be measured with any other technology on the market, will help you to understand how the machine is running and to identify the operating conditions that generate most stress in it. At the same time, it lets the end user explore different options to maximise the useful life of the machine, such as modifying the working conditions, re‑engineering the materials or varying the technical specifications.

This technology also makes it possible to take action ahead of a possible failure as it allows trends to be identified, helping you to take the necessary precautions so that you do not have to stop the process unexpectedly.

Beating bad practice

With the OilWear sensor, bad practices of measuring wear can be beaten. The most usual way of detecting the deterioration of the machine in order to anticipate it is to carry out a periodical inspection, in which the evidence is observed after it occurs. Also, these inspections are complemented with monitoring of the state of the oil in a laboratory. However, this approach presents a series of drawbacks: when samples are analysed in a laboratory the contamination is measured at a representative point. If it is in a system with recirculation that is fitted with filters, the data could be untrue since these absorb most of these particles, and depending on the sampling point it may not be significant. OilWear makes a dynamic measurement of the type of particles and how they are detaching in certain critical points of the machine.

An end to unplanned down time in the system

The direct consequence of not knowing that excessive wear is being caused in a machine can be unplanned down time, with the high cost that that involves. Moreover, it is possible that when an emergency situation arises no assessment is made of the causes that led to that incident. As well as the costs to the actual production process, bad practice is generated in setting up by the urgency of putting the process back into operation.

OilWear reveals wear conditions of and key variations

The OilWear sensor not only shows which wear conditions exist, but it also shows whether there are variations connected with the operation of the machine. Its added value is that it detects the rate and type of generation of particles and identifies the cause of their appearance as no other technology is capable of doing at this time. OilWear reveals whether the problem is caused by adhesive wear, abrasive wear, fatigue or corrosion. Depending on the predominant type of particles that are detected, the customer can be guided as to what actions should be taken since it is possible to adopt specific solutions to meet each case.

If, for example, it reveals a problem due to fatigue, it is highly probable that it is a result of the quality of the material or the stress to which the machine is subjected. If what is observed is an increase in particles from a phenomenon of adhesive wear, it is very likely that it will be due to the state of the lubricant or to incorrect assembly.

Patterns of wear in the machine

The monitoring by the OilWear sensor makes it possible to identify the origin and patterns of wear in the machine. In addition, it provides added value by uniting the information of how the system wear is behaving during the various stages of operation. OilWear not only indicates when that situation is produced but also how and why, which is valuable information for preventing unexpected stoppages.

Identification of the quantity of air

Thanks to its advanced technology, OilWear identifies the quantity of air in the lubrication system. The excessive presence of air generates accelerated oxidation in the fluid, with the consequent degradation and reduction of the useful life of the system. The air enters the system in the form of bubbles, and if they make contact with the lubricated parts under conditions of high pressure that can lead to their implosion and, as a consequence, impacts in those points. This phenomenon, called cavitation, causes loss of material, which in turn induces wear. The presence of air in the work zone can cause a loss of efficiency of the lubrication and the non-generation of the necessary lubricant film, with the consequent problems that this causes.

Sensitivity range and information mapping

Many of the sensors that are available on the market, even those that can measure below four microns, offer a snapshot view that fluctuates but they are not able to make an assessment of trends or perform more global calculations. OilWear makes it possible to develop an extensive digital treatment of the information for an in depth correlation of data. The device provides information in real time in a way that is clear, fast and customer oriented because the process for obtaining data ends with the delivery of an easy to understand and friendly report.

Simple fitting and maintenance without stoppage

Depending on the application OilWear can be installed in less than two hours by means of a bypass. After this short time it is all ready to provide specific information that is simple to understand. The key for obtaining relevant information about the system that is being monitored is to select a suitable installation point for each case. The requirements for installation are very simple; a pressure greater than 2 bars and a small flow rate (between 0.1 and 1.5 litres per minute) which does not affect the lubrication system. The installation is done with just two pipes, one for input and the other for outlet, and two connecting tubes, one for communication and another for feed. Whereas other sensors that are installed in the principal pipework of the lubrication system require the machine to be stopped to be recalibrated, repaired or replaced, with OilWear there is no need to interrupt the operation to carry out maintenance work on the sensor.

OilWear is an advanced technological solution for monitoring of fluids with which it is possible to identify both the origin and the patterns of wear in a critical machine. Thanks to its analysis of the different states of operation of the system the sensor indicates the moment when the wear appears and the causes of its origin. All of that makes it the best and most complete source of information for taking correction measures and anticipating possible unplanned down time in the system.