Oil analysis system detects early damage to gears

The FAG Wear Debris Monitor is designed to provide plant operators with a reliable system that prevents unplanned downtime and minimises maintenance, repair and overhaul costs. According to the company, it is capable of pinpointing the precise location of any damage or wear to gears, bearings and cages within a gearbox or other industrial gear unit. The device'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 filer, or as a separate circuit. The device 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. It is optimised to provide information on the number of particulates present in the oil before classifying these according to their physical size. Suitable for use in a range of industries, the FAG Wear Debris Monitor can be set up to operate in conjunction with online condition monitoring systems, including Schaeffler's FAG DTECT X1, FAG WiPro or FAG ProCheck systems. This means that companies can also monitor the vibration behaviour of the machine and its components, including rolling bearings and gear wheels. "By detecting damage early, and by using the wide variety of analysis methods, the operational reliability of gears can be improved significantly, leading to similar improvements in productivity," said Schaeffler's Christian Meindl.