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FAG Wear Debris Check

presented by
FAG Wear Debris Check
Agenda

1 Why monitor the lubricant?

2 Monitoring methods

3 Wear performance of industrial gearboxes

4 Product features

5 Data integration

6 Conclusion

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FAG Wear Debris Check
Why monitor the lubricant?
Construction Lubricant

Material selection
Chemical & physical
Gear geometry properties
Production precision Type of oil
Surface treatment and Additives
Surface roughness

Availability

Operation Monitoring

Load type
Gear forces and Online
additional forces Offline
circumferential speed On-Site
Temperature

Many oil lubricated aggregates such as modern industrial gear boxes have
high demands regarding availability.

Lubrication monitoring helps to increase the availability and optimize the


useable life expectancy of the machinery.

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FAG Wear Debris Check
Why monitor the lubricant?

Particle
Machine condition

Vibration

FAG Wear Debris Check


Noise

depends on the
cause of damage Temperature

Machine breakdown

Days
Weeks
Months
Prewarning time
Depending on the cause of the damage the lubricant monitoring results in an early detection
of machine breakdowns.

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FAG Wear Debris Check
Monitoring methods

Offline OnSite Online


(Laboratory) (portable (integrated
equipment) sensors)

Water (solved and absolute)

Viscosity

Oil-quality

Particle (ISO/SAE, ppm, Fe, NFe/Fe)

There are many parameters which can be monitored at oil in continuous or periodic
intervals.
The continuous monitoring of the particle entry (nFe/Fe) has a direct referring to the wear of
bearings and gear tooth systems.
FAG Wear Debris Check
Wear performance of industrial gearboxes
The useful determination of the wear behavior of industrial gear boxes starts at particle sizes
>10m.

Total gear box


damage

Advanced damage

Start of heavy damage

Beginning damage

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FAG Wear Debris Check
Wear performance of industrial gearboxes
Bearings and Bearing cages The metallurgical differentiation
Cause of damage

gear tooth systems (Brass) of the detected particles allows a


identification of the cause of
damage (case by case).
Particle

Particle
Fe nFe Fe nFe

Fe: Ferromagnetic particle (e.g. iron)


nFe: Non-ferromagnetic particle (e.g. brass)

Detection of smaller Detection of greater A direct correlation of the


Progress of damage

particle particle characteristic values "particle per


minute" and "particle mass per
hour" allows the identification of
Particle

Particle

the progress of damage.

P / Min. P-Mass / h P / Min. P-Mass / h

P / Min.: Particle per minute Particle rate


P-Mass / h: Particle mass [g] per hour

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FAG Wear Debris Check
Product features
Depending on the type of damages machine problems could be detected much more earlier by
lubricant monitoring than by other monitoring methods.

Tasks of the FAG Wear Debris Check:


Detection and classification of wear on gear boxes, bearings and bearing cages.
Monitoring of large industrial gear boxes across industries

Very early detection of damages in bearings and gear wheels


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Classification of metal particles (material & size)

2
Assessment of cause of damage,

3 measure of damage and damage


development

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FAG Wear Debris Check
Product features
Characteristics

Monitoring of mineral-, synthetic oils and water/oil emulsions

Classification of metal particles (Fe/ nFe)

Data communication (digital & analogue)

Fluid temperature: -20C to 85C

Fluid pressure: max. 20 bar

Technical advantages
No calibration necessary

Integration also in existing monitoring systems possible


Customer value
Reliable predictions of the machine status
Improvement of maintenance intervals and cost decrease
Intelligent process monitoring

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FAG Wear Debris Check
Product features
Scope of delivery

FAG Wear Debris Check (083068007-0000-10)

Manual (dt./ engl.)

Software CD with configuration- and analysis software


"FAG Wear Debris Analyzer"

Erection bolts incl. vibration damper

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FAG Wear Debris Check
Data integration
Direct communication to FAG Wear Debris Analyzer
(local PC)
Partikelkonzentration Mischergetriebe
TCP/IP

(Formsandaufbereitung, Gieerei)

450000

400000

Table calculation 350000

300000
FE 100-200um
OEM

Anzahl Partikel (kum.)


Fe 200-400um
Fe 400-800um
250000 Fe >800um

MRO
Nfe 150-200um
200000 NFe 200-400um
NFe 400-800um
150000 NFe 800-1600um
NFe>1600 um

100000

50000

0
FAG WEAR DEBRIS CHECK

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84

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00

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0
72
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2 88

0
4 32

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7 92

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1 00

1 22

1 36

1 51

1 65

1 87
1 94
10
11

12

14

15

17
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Betriebsstunden

Analysis/ Visualization

PLC / Fieldbus Software PLC


Machine
control

OEM

Analysis Visualization

Condition Monitoring System FAG Viewer


Monitoring
Condition

A OEM
MRO
4-20 mA

Analysis Visualization

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FAG Wear Debris Check
Conclusion
Advantages of the FAG Wear Debris Check

Efficient detection of damages

Reliable predictions of the machine status

Easy integration of the FAG Wear Debris Check

Intelligent process monitoring

Services from a single source

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FAG Wear Debris Check
Strengths / limitations

Strengths Limitations

Very early detection on bearings and tooth No localization of the damage possible
systems
Not suitable for greased bearings
Detection of gear damage
even outside the load zone
Detection of cage damages (metal) on
bearings
Suitable for very slow rotating machines
Easy and clearly interpretable metrics

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