Assessment of Condition Diagnosis System for Axles with Ferrous Particle Sensor

Hong, Sung-Ho; Jeon, Hong-Gyu

doi:10.3390/ma16041426

Cited by 3 publications

(4 citation statements)

References 33 publications

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“…The damage caused by varnish contamination can be prevented by regularly analyzing the properties of the lubricants and its contamination levels. Both the offline method of analyzing the lubricating oil through oil sampling and online or inline method using sensors are widely used [ 68 , 69 ]. When varnish contamination occurs in hydraulic oil, the dielectric constant shows distinct variations compared to that of the new oil because the dielectric constant is largely expressed as a sum of two types of polarizability and a dipole moment, where the generation of varnish affects the dipole moment due to oxidation [ 69 , 70 ].…”

Section: Varnishmentioning

confidence: 99%

Varnish Formation and Removal in Lubrication Systems: A Review

Hong

Jang

2023

Materials

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This study presents the current literature regarding the investigation of varnish contamination among the various types of lubricant contaminations. As the duration of use of lubricants increases, the lubricant deteriorates and may become contaminated. Varnish has been known to cause filter plugging, sticking of the hydraulic valves and fuel injection pumps, flow obstruction, clearance reduction, poor heating and cooling performance, and increased friction and wear in various lubrication systems. These problems may also result in mechanical system failures, performance degradation, and increased maintenance and repair costs. To improve the problems caused by varnish contamination, an adequate understanding of varnish is required. Therefore, in this review, the definitions and characteristics, generating machinery, generating mechanisms, causes, measurement methods, and prevention or removal methods of varnish are summarized. Most of the data presented herein are reports from manufacturers related to lubricants and machine maintenance that are included in published works. We expect that this summary will be helpful to those who are engaged in reducing or preventing varnish-related problems.

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Section: Varnishmentioning

confidence: 99%

Varnish Formation and Removal in Lubrication Systems: A Review

Hong

Jang

2023

Materials

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“…Among oil sensors, the development of sensors for wear particles accounts for a large proportion, and among them, ferrous wear debris sensors are widely used for condition diagnosis because iron is widely used as a component of mechanical systems, and the generation of wear particles is a major indicator for abnormality diagnosis [8][9][10][11]. This study focused on the application of a ferrous wear debris sensor with a permanent magnet.…”

Section: Introductionmentioning

confidence: 99%

“…This sensor can accumulate ferrous wear particles by use of a permanent magnet, so the sensor can not only measure the number of ferrous wear particles, but also prevent three-body abrasive wear. In previous research [10], different results have been obtained depending on the location of a ferrous wear debris sensor with a permanent magnet to diagnose the condition of an axle in construction equipment. Here, the axle performs a function similar to that of a gearbox.…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis for Appropriate Positioning of Ferrous Wear Debris Sensors with Permanent Magnet in Gearbox Systems

Hong

2024

Sensors

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In order to improve the measurement sensitivity of ferrous wear debris sensors with a permanent magnet, a new numerical approach to the appropriate position of the sensor is presented. Moreover, a flow guide wall is proposed as a way to concentrate flow around the ferrous particle sensors. The flow guide wall is intended to further improve measurement sensitivity by allowing the flow containing ferrous particles to flow around the sensor. Numerical analysis was performed using the multi-physics analysis method for the most representative gearbox of the sump-tank type. In condition diagnosis using ferrous wear debris sensors, the position of the sensor has a great influence. In other words, there are cases where no measurements occur, despite the presence of abnormal wear and damage due to the wrong sensor position. To determine the optimal sensor position, this study used flow analysis for the flow caused by the movement of the gear, electric and magnetic field analysis to implement the sensor, and a particle tracing technique to track particle trajectory. The new analysis method and results of this study will provide important information for selecting the optimal sensor location and for the effective application of ferrous wear debris sensors, and will contribute to the oil sensor-based condition diagnosis technology.

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“…This sensor is capable of distinguishing between fine and coarse debris. It can prevent abrasive wear and damage because of the accumulation of ferrous particles of the permanent magnet [ 30 ]. Due to these advantages, its utilization is increasing among ferrous particle sensors.…”

Section: Introductionmentioning

confidence: 99%

Numerical Approach and Verification Method for Improving the Sensitivity of Ferrous Particle Sensors with a Permanent Magnet

Hong

2023

Sensors

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This study aimed to improve the sensitivity of ferrous particle sensors used in various mechanical systems such as engines to detect abnormalities by measuring the number of ferrous wear particles generated by metal-to-metal contact. Existing sensors collect ferrous particles using a permanent magnet. However, their ability to detect abnormalities is limited because they only measure the number of ferrous particles collected on the top of the sensor. This study provides a design strategy to boost the sensitivity of an existing sensor using a multi-physics analysis method, and a practical numerical method was recommended to assess the sensitivity of the enhanced sensor. The sensor’s maximum magnetic flux density was increased by around 210% compared to the original sensor by changing the core’s form. In addition, in the numerical evaluation of the sensitivity of the sensor, the suggested sensor model has improved sensitivity. This study is important because it offers a numerical model and verification technique that may be used to enhance the functionality of a ferrous particle sensor that uses a permanent magnet.

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Assessment of Condition Diagnosis System for Axles with Ferrous Particle Sensor

Cited by 3 publications

References 33 publications

Varnish Formation and Removal in Lubrication Systems: A Review

Varnish Formation and Removal in Lubrication Systems: A Review

Numerical Analysis for Appropriate Positioning of Ferrous Wear Debris Sensors with Permanent Magnet in Gearbox Systems

Numerical Approach and Verification Method for Improving the Sensitivity of Ferrous Particle Sensors with a Permanent Magnet

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