Lubrication oil condition monitoring and remaining useful life prediction with particle filtering (original) (raw)
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TECHNICAL SYSTEM CONDITIONS MONITORING VIA THE LUBRICATING OIL ANALYSIS
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Oil monitoring consists of measuring the condition and changes in the structure and characteristics of engine oil over time of exploration. The tests performed on the oil sample give three pieces of information: the condition of the lubricated system, the type of impurities present, and the condition of the oil itself. The state of the system is defined by the number and type of particles, as well as by the change of these parameters with time. The condition of the oil is mostly defined by changes in viscosity, decrement in additives amount, contamination, etc. Proper oil monitoring enables an optimization of the working life of the lubricated system. Namely, the main cause of failure in the lubricated system is the presence of abrasive particles in the oil, which are often products of wear. Therefore, an analysis of wear and contamination must be performed, and the damage and cause of failure must be determined. Considering that it is impossible to eliminate wear, it is necessary to define the critical values of wear for the operation of the system and find the main causes of wear. Intensive wear occurs with an increase in the number of large particles in the entire fluid volume, while in normal wear the particles are of small dimensions. The material from which the particles are made is also of great importance, through which we can determine the origin of the abrasive. Zn, Ca, Ba and Mg indicate the consumption of additives. Fe, Pb, Cu, Cr, Ag, Sn, Mn, and Al indicate wear. Penetration of the coolant into the lubricating oil is indicated with the appearance of Na and B, and the increased content of Ca and Si indicates the contact of the oil with air or malfunction of the air filter. Oil sampling must be carried out exactly in a certain way and on a certain part of the system through which the oil flows. Worn particles tend to settle to the bottom of the oil tank, larger particles settle faster and smaller ones more slowly. If we take a sample by simply draining the oil from the reservoir, we can get an unrealistic picture of the actual condition of the lubricated system.
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Due to the spread of carbon neutral, the effective use of lubricant has been drawing attention. Since the main component of lubricant is petroleum-derived hydrocarbon oil, reducing the amount used by 1 kg will reduce CO2 by approximately 3 kg. The value of CO2 reduction is very important. In order to reduce the amount of lubricant used, there is a movement to reduce the frequency of lubricant exchange or continue to use lubricant without exchanging it. However, it is known that lubricant-induced mechanical failures occur. For this reason, equipment condition monitoring using oil sensors has been spread. The color of the lubricant, also called machine blood, indicates the condition of the machine. The oil sensor measures contamination, which has a fatal effect on machine failure, and oxidation degradation, which is related to the performance of lubricant and the machine failure. Contamination includes water and wear debris, and oxidative degradation includes consumption of additives ...
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Every year high costs are expending to repair rotating machinery in factories and industrial centers due to failures. Most failures happen suddenly while by condition monitoring of systems prognosis and diagnosis are possible. By condition monitoring, the failures can be detected and solved in the early stages. Gearboxes are an element used widely, and applying condition monitoring for them makes a significant benefit for saving budget due to prognosis and removing failure before progress. The current paper aims to present a condition monitoring system for gearbox which is able to inspect lubricant by oil temperature and pH. Moreover, it can detect some defects in the gearbox by vibration analyses such as unbalance, bent shaft, looseness in bearing housing, and whirl of oil. The evaluation of the system shows that its accuracy is proper for use in gearboxes.