New maintenance concepts thanks to continuous oil monitoring
Hydraulic and lubrication systems are an essential part of mobile machines in which oil plays a series of important roles. The oil transmits power, lubricates, manages heat and transports dirt to the filters. Scientific studies have shown that malfunctions in hydraulic and lubrication systems are predominantly caused by wear, contamination, deterioration, mixing or extreme temperature fluctuations.
It is, therefore, crucial that the oil is in proper working order. Knowing the current condition of the oil also provides information as to the condition of the machine at the same time.
Unlike individual oil samples, continuous condition monitoring or so-called Online Condition Monitoring“(OCM), of the oil and the filters enables predictive analysis and early detection of failures.
Detectable causes of failures include contamination of the oil by water, dirt, increased wear, mixing with other fluids and the use of the wrong oil. In addition, OCM enables better documentation of service measures including oil changes and maintenance. Intelligent OCM sensors can extend maintenance and oil change intervals and prevent production downtimes, leading to a significant reduction in operating costs.
To cover all aspects of monitoring the condition of oil, ARGO-HYTOS has added two new sensors to its product range: The LubCos Visplus and the LubCos Level. In addition to measuring the temperature and dielectricity, the LubCos Visplus also measures viscosity in particular. Like the LubCos H2Oplus, the LubCos Level is equipped with intelligent condition monitoring that, among other things, detects the remaining useful life of the oil (RUL), the water content and an oil mixture. However, the LubCos Level also enables continuous level measurement, which can replace existing level and temperature sensors. This facilitates system integration and offers additional savings potential by making other sensors redundant.
Furthermore, the LubCos H2Oplus and the OPCom have been fundamentally redesigned in keeping with customer requirements as regards communication, simple operation and size. Both sensors now fulfil CANopen standards, just as the LubCos Level and the LubCos Visplus, and are thus suitable for mobile application.
The OCM sensors are completed with the addition of a new display and memory unit, the LubMon Visu. It is compatible with all ARGO-HYTOS OCM sensors and in addition, any analogue sensors you want can be connected to it. LubMonVisu features a graphic display, a USB connection, an SD card reader, a real time clock, an internal data memory, an optional Ethernet interface with web server, as well as switching contacts for alarm management. In addition to other accessories, a printer can also be connected to the module.
With its CM products, ARGO-HYTOS has all the aspects of Fluid Condition Monitoring covered. From stationary systems to mobile applications and right down to the service area, ARGO-HYTOS is your complete partner for solutions from one source.
UMPC 045 - programmable cleanliness class
Using the mobile UMPC 045 oil service unit, hydraulic and lubricating systems can be easily filled or cleaned. The UMPC
045 is equipped with hoses and filter element and is ready to be connected. For easy transport, electrical cables as
well as vacuum and return hose, are mounted on support brackets on the machine frame. The ergonomic design
permits easy handling even where space is at a premium.
An integrated particle monitor constantly monitors the oil cleanliness level. Data can be transmitted to a PC via an RS 232
interface, and the cleanliness gradient can be shown graphically or tabulated, and tracked. Up to 500 measurements
can be saved in memory and downloaded at a later point.
NEW: The target cleanliness level can now be programmed using an add-on module. Once the target cleanliness level has been reached, an indicator light shows and the pump switches off automatically.
OPCom II - Particle monitor of a wide range of applications
Oil purity is the essential oil parameter for the reliable operation of valves and pumps. High concentrations of particles can cause components to malfunction or become damaged. In addition, an
increase in particle concentration can also indicate that there is a damaged component or an increased dirt entry. Monitoring oil purity online makes it possible to detect changes in the particle
concentration immediately and take suitable action. That is the reason why the monitoring of oil purity is increasingly performed online. For more than 5 years, ARGO-HYTOS has offered its
online particle monitor OPCom as part of its product range. When overhauling this product series, ARGO-HYTOS paid
particular attention to the product‘s functional design and versatile communication options. Consequently, the OPCom II now comes standard with a CAN-BUS in addition to a serial port
and an analog 4...20 mA output. What is more, the OPCom II is also equipped with two additional digital interfaces, an
alarm output and an input used to start and stop the measurement externally. These interfaces and functional features
allow the online particle monitor to be integrated effortlessly into higherranking control systems, e. g. those installed in test stands or machine controllers. The measurements can be taken both time-controlled and depending on machine or testing cycles.
Thanks to its compression resistance of 420 bar and its extraordinarily compact design the OPCom II is suitable for a
wide range of different applications.
Off-line Filtration - Trends in Technology
Are there specific types of off-line filtration which are increasingly used? If so, why?
Yes, we see that the demand for mobile units with integrated sensors is growing. Experienced maintenance and service employees nowadays are aware about the fact that off-line filtration reduces the operating costs of hydraulic machines.
Additionally, more and more standards, manufacturer and quality guidelines demand to protocol the cleanliness of the oil. This ensures that service measures have been carried out carefully and thereby prevent damages or still stand.
Is there a greater need for off-line filtration since plants/machines become more compact and have less room for on-board filtration?
The trend to reduce the fluid volume in machines increases the stress on the oil caused by heat, oxidation and particles. To cope with this higher stress, better oils and additives are needed, along with an improved service strategy. Off-line filtration allows to improve the oil condition and increase the lifetime of the used oil and machine without wasting precious space and weight during normal operation.
Do you see changes in how/why filter carts/off-line filtration are being used?
Besides the cost saving effect, off-line filtration gives the user higher flexibility and safety. A machine can not only be serviced in a fixed interval, but when the oil condition makes it necessary. The initial oil quality and the result of the purification process are measured by the integrated sensors what improves the handling, since no oil samples have to be taken and analyzed. This feature is also used at end-of-line quality checks to assure and proof system cleanliness and health.
What is the biggest trend in off-line filtration design and use?
Along with the trend of making the units smarter, by integration of oil condition sensors, we see that customers want the units to be simple and intuitive to operate. Additionally, the physical parameters like flow, viscosity and temperature have been extended to suit more applications. Modern off-line filtration systems also do not only filter particles, but also water and air from the oil. All these developments help to further improve the benefit of off-line filtration units and the health of the system and thereby substantially reduce costs.