New Product Info
FAG Wear Debris Monitor(Sep 21,2010)
FAG Industrial Services (F’IS) has extended its portfolio of online condition monitoring products by adding an oil sensor, the FAG Wear Debris Monitor. The combination of oil monitoring and vibration monitoring permits a very early detection of damage to large industrial gears and a precise location of their point of origin within the unit. This offers plant operators even more extensive protection for gear units, helping them to avoid unplanned shutdowns and minimize maintenance costs.
Heavy duty industrial gears require excellent maintenance as their smooth operation is often decisive for a plant’s overall availability. If any damage develops in such a gear, this means not only high repair costs but also costly production disruptions as well as secondary damage.
One damage detection method is vibration monitoring. Sensors are installed on the machine to be monitored. These sensors control the vibration behavior of the machine and its components, such as rolling bearings or gearwheels. Changes in the running behavior are early signs of damage, which allow to initiate suitable repair and maintenance measures in time to prevent machine failure. Oil analysis is an ideal complement to vibration monitoring. With the help of oil analysis, emerging damage in some gear types, such as planetary gears in wind turbines, can be detected earlier than with vibration monitoring alone.
That is why F’IS has added the FAG Wear Debris Monitor to its range of online condition monitoring solutions. The new oil sensor can be installed easily in the by-flow, in front of the oil circuit filter in a gear unit, or as a separate circuit. Its functional principle is based on the fact that wear on components like bearings or gearwheels is evidenced by rubbed-off metal particles several months before an actual failure. The rubbed-off particles are clearly visible in the oil. The FAG Wear Debris Monitor distinguishes ferrous metals from non-ferrous metals, monitors the number of particles in the oil, and classifies the particles according to size and material. This enables the device to detect signs of damage at a very early stage.
A further novelty is that the FAG Wear Debris Monitor can be integrated easily into existing FAG online condition monitoring systems. This makes it possible to adapt and retrofit the system according to a customer’s specific requirements.
The combination of oil particle monitoring and vibration monitoring permits a very early detection and identification of damage as well as a precise location of its point of origin within the gear. Both measuring methods complement each other perfectly.
After a damage has been detected, a professional damage analysis must be carried out to determine the causes. The derivation of specific recommendations allows to prevent the development of similar damage in the future. F’IS has a large range of analysis methods at its disposal. Endoscopy, for example, is used to determine the extent and severity of the damage by inspecting the inside of a machine with the help of digital endoscopes. F’IS experts then make a diagnosis on the basis of the images (photos and videos).
“The combined use of FAG oil monitoring products and vibration monitoring products as well as F’IS services provides an effective and cost-efficient way to improve the protection of oil circulation lubricated gears. By means of the early detection of damage, and the large range of analysis methods the operational reliability of gears is increased and the overall productivity rises permanently’, says Christian Meindl, Product Manager of F’IS Oil Monitoring Products.
FAG Industrial Services (F’IS) has extended its portfolio of online condition monitoring products by adding an oil sensor, the FAG Wear Debris Monitor. The combination of oil monitoring and vibration monitoring permits a very early detection of damage to large industrial gears and a precise location of their point of origin within the unit. This offers plant operators even more extensive protection for gear units, helping them to avoid unplanned shutdowns and minimize maintenance costs.
Heavy duty industrial gears require excellent maintenance as their smooth operation is often decisive for a plant’s overall availability. If any damage develops in such a gear, this means not only high repair costs but also costly production disruptions as well as secondary damage.
One damage detection method is vibration monitoring. Sensors are installed on the machine to be monitored. These sensors control the vibration behavior of the machine and its components, such as rolling bearings or gearwheels. Changes in the running behavior are early signs of damage, which allow to initiate suitable repair and maintenance measures in time to prevent machine failure. Oil analysis is an ideal complement to vibration monitoring. With the help of oil analysis, emerging damage in some gear types, such as planetary gears in wind turbines, can be detected earlier than with vibration monitoring alone.
That is why F’IS has added the FAG Wear Debris Monitor to its range of online condition monitoring solutions. The new oil sensor can be installed easily in the by-flow, in front of the oil circuit filter in a gear unit, or as a separate circuit. Its functional principle is based on the fact that wear on components like bearings or gearwheels is evidenced by rubbed-off metal particles several months before an actual failure. The rubbed-off particles are clearly visible in the oil. The FAG Wear Debris Monitor distinguishes ferrous metals from non-ferrous metals, monitors the number of particles in the oil, and classifies the particles according to size and material. This enables the device to detect signs of damage at a very early stage.
A further novelty is that the FAG Wear Debris Monitor can be integrated easily into existing FAG online condition monitoring systems. This makes it possible to adapt and retrofit the system according to a customer’s specific requirements.
The combination of oil particle monitoring and vibration monitoring permits a very early detection and identification of damage as well as a precise location of its point of origin within the gear. Both measuring methods complement each other perfectly.
After a damage has been detected, a professional damage analysis must be carried out to determine the causes. The derivation of specific recommendations allows to prevent the development of similar damage in the future. F’IS has a large range of analysis methods at its disposal. Endoscopy, for example, is used to determine the extent and severity of the damage by inspecting the inside of a machine with the help of digital endoscopes. F’IS experts then make a diagnosis on the basis of the images (photos and videos).
“The combined use of FAG oil monitoring products and vibration monitoring products as well as F’IS services provides an effective and cost-efficient way to improve the protection of oil circulation lubricated gears. By means of the early detection of damage, and the large range of analysis methods the operational reliability of gears is increased and the overall productivity rises permanently’, says Christian Meindl, Product Manager of F’IS Oil Monitoring Products.
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