2015-Sustainable Industrial Processing Summit
SIPS 2015 Volume 7: Ionic Liquids & Energy Production

Editors:Kongoli F, Gaune-Escard M, Mauntz M, Rubinstein J, Dodds H.L.
Publisher:Flogen Star OUTREACH
Publication Year:2015
Pages:310 pages
ISSN:2291-1227 (Metals and Materials Processing in a Clean Environment Series)
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    Innovative Approach with the Oil Condition Monitoring System Wearsens®: Continuous, Online Detection and Control of Friction Loss and Wear

    Manfred Mauntz1; Ulrich Kuipers2; Jorn Peuser1;
    1CMC INSTRUMENTS GMBH, Eschborn, Germany (Deutschland); 2UNIVERSITY OF APPLIED SCIENCE SOUTHWESTPHALIA, Hagen, Germany (Deutschland);
    Type of Paper: Regular
    Id Paper: 39
    Topic: 17


    A new oil sensor system is presented for the continuous, online measurement of the wear in industrial gears, turbines, generators, transformers and hydraulic systems. Detection of change is much earlier than existing technologies such as particle counting, vibration measurement or recording temperature. Thus targeted, corrective procedures and/or maintenance can be carried out before actual damage occurs. Efficient machine utilization, accurately timed preventive maintenance, a reduction of downtime and an increased service life and can all be achieved.<br />The oil sensor system measures the components of the complex impedances X of the oils, in particular the electrical conductivity, kappa and relative dielectric constant, epsilon r, and the oil temperature T. The values kappa and epsilon r are determined independently.<br />Inorganic compounds occur at contact surfaces from the wear of parts, broken oil molecules, acids or oil soaps. These all lead to an increase in the electrical conductivity, which correlates directly with the wear. In oils containing additives, changes in dielectric constant infer the chemical breakdown of additives. A reduction in the lubricating ability of the oils, the determination of impurities, the continuous evaluation of the wear of bearings and gears and the oil aging all together follow the holistic approach of real-time monitoring of changes in the oil-machine system.<br />Different application examples from the industrial sectors wind energy and gearbox test stands and will be presented.


    oil sensor system, oil aging, bearing wear, online condition monitoring, preventive maintenance, oil additive degradation, white etching cracks, industrial gearboxes, critical vibration loading


    [1] Gegner, J., Kuipers, U. and Mauntz, M.: Ölsensorsystem zur Echtzeit-Zustandsüberwachung von technischen Anlagen und Maschinen, Technisches Messen 77, 2010, pp. 283-292
    [2] Kuipers, U., Mauntz, M.: Ölsensorsystem – Sensorsystem zur Messung von Komponenten der komplexen Impedanz elektrisch gering leitender und nichtleitender Fluide, dessen Realisierung und Anwendung, Patentanmeldung Nr. 10 2008 047 366.9, Anmelder: cmc Instruments GmbH, Deutsches Patentamt, München, Anmeldetag: 15. 9. 2008
    [3] Kuipers, U., Mauntz, M.: Verfahren, Schaltungsanordnung, Sensor zur Messung physikalischer Größen in Fluiden sowie deren Verwendung, Europäische Patentanmeldung Nr. EP 09000244, Europäisches Patentamt, München, 9. 1. 2009
    [4] MTS, Wind Turbine Testing solutions, Minnesota, 2012
    [5] Gegner, J., Kuipers U. and Mauntz, M.: New Electric Online Oil Condition Monitoring Sensor – an Innovation in Early Failure Detection of Industrial Gears, The 4th International Multi-Conference on Engineering and Technological Innovation July 19th – July 22nd, 2011, Orlando, Florida, USA 2011, Proceedings Volume I, International Institute of Informatics and Systemics, Winter Garten, FL, USA, 2011, pp. 238-242
    [6] Gegner, J., Kuipers U. and Mauntz, M.: High-precision online sensor condition monitoring of industrial oils in service for the early detection of contamination and chemical aging, Sensor + Test Conferences 7.-9.6.2011, Nürnberg, AMA Service GmbH, Wunstorf, 2011, pp. 702-709
    [7] Gegner, J., Klingauf, S., Kuipers, U., Mauntz, M.: Continuous Wear Measurement in Tribological Systems to Control Operational Wear Damage with a new Online Oil Sensor System, TAE Technische Akademie Esslingen, 19th International Colloquium Tribology, Esslingen, January 21-23, 2014, 23.01.2014

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    Cite this article as:

    Mauntz M, Kuipers U, Peuser J. Innovative Approach with the Oil Condition Monitoring System Wearsens®: Continuous, Online Detection and Control of Friction Loss and Wear. In: Kongoli F, Gaune-Escard M, Mauntz M, Rubinstein J, Dodds H.L., editors. Sustainable Industrial Processing Summit SIPS 2015 Volume 7: Ionic Liquids & Energy Production. Volume 7. Montreal(Canada): FLOGEN Star Outreach. 2015. p. 257-266.