The new FAG Wear Debris Check oil sensor allows damage to oil-lubricated machines such as industrial gearboxes and contamination in oil circuits to be detected at a very early stage. When combined with a vibration monitoring device or integrated into the customer’s system, the sensor provides machine operators with even more comprehensive protection for their machines. The monitoring of abraded particles in the oil and the simultaneous vibration analysis make it possible to precisely localize the damage and plan corrective measures. Functioning without problems is often vital to machines’ overall availability, especially in the case of industrial gearboxes that are subjected to high loads, e.g. drives for the raw material extraction. If damage occurs, there is usually a danger of costly downtimes and subsequent damage in addition to the repair costs. In many industrial processes, contamination in oil and lubricant circuits causes severe loss of quality. However, the FAG Wear Debris Check makes it possible to prevent unplanned failures, identify influencing factors that negatively affect quality at an early stage, and significantly reduce maintenance costs.
The FAG Wear Debris Check monitors the number of particles as it increases and evaluates them based on their size and material (Fig.). The sensor can easily be installed in front of the filter in the partial flow of the gearbox’s oil circuit. It is also possible to create a separate circuit in which to install the oil sensor. The sensor can also be quickly and easily integrated into existing condition monitoring and control systems via its interfaces, such as Ethernet. The direct integration of the sensor into the process control system allows the performance of the machine and the quality of the products to be optimized, and combing it with a vibration measuring device delivers the optimum solution for reliably monitoring machines and equipment. The precise inspection of the material properties of the abraded particles in the oil and a simultaneous frequency-selective vibration analysis make it possible to determine exactly which components are defective in the gearbox.