電力設備測試 > 風力發電機維護測試
潤滑油狀態線上持續監測系統
cmc Oil Sensor System 型號：WearSens® WS3000- 一種新的預防齒輪箱與軸承故障的方法 - 線上持續監測！
- 在損壞發生前，即偵測出異常變化；在損壞開始前，即提供預警。
- 優化負載，減少磨損；即時進行預測性維護；預防磨擦性磨損。
- 偵測添加劑的消耗。
- 應用領域：船舶、重型機具、離岸風力發電機、汽車測試台、礦業。
- 應用目標：風力發電機齒輪箱、污染偵測、滾子軸承磨損偵測、油品變質監測、油品狀態監測解決方案。
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- 一種新的預防齒輪箱與軸承故障的方法 - 線上持續監測！
- 在損壞發生前，即偵測出異常變化；在損壞開始前，即提供預警。
- 優化負載，減少磨損。
- 即時進行預測性的維護。
- 預防磨擦性磨損。
- 偵測添加劑的消耗。
- 專利測量方法。
- 比振動監測及實驗室分析更靈敏。
- 容易安裝或改裝。
- 基於網路的分散式監測。
- 依據以WearSens®監測的油品狀態制定維護計劃，可節省巨額成本。
- 應用領域：
- 船舶。
- 重型機具。
- 離岸風力發電機。
- 汽車測試台。
- 礦業。
- 應用目標：
- 風力發電機齒輪箱。
- 污染偵測。
- 滾子軸承磨損偵測。
- 油品變質監測。
- 油品狀態監測解決方案。
- 技術說明：
- 適用於及早的故障偵測、從啟動開始即偵測的機械中的變化 – 早在故障狀態發生前。
- 應用包括：
- 風力發電機，包括離岸（風力發電機組）。
- 油絕緣式渦輪機，包括熱電共生設備。
- 潤滑劑性能分析。
- 汽車及船舶應用測試台。
- WearSens®從啟動的第一天開始 – 早在損壞發生前，即偵測機械品質的早期變化。相對於在損壞發生後才偵測出異常的振動監測系統、油粒分析儀與濾油系統，這代表了一大進步。
- cmc原廠與其學術界及產業界合作夥伴，對於磨擦性磨損如何發生有一個透徹的瞭解。首先，由於滾子軸承的通過，而出現非常小的細線裂紋，油進入此裂縫，局部的振動及溫度上升，使油降解成油皂、酸及氫，然後氫造成周圍金屬的脆化，加速軸承剪切的可能性及隨後的點蝕凹坑。
- 工業齒輪箱中過早的軸承故障，通常是因為滾道表面內的裂縫造成摩擦誘導性的振動負載所導致。
- 及早偵測出潤滑劑的臨界狀態，可在傳動軸上進行預防性維護 – 在損壞發生前。
- 風力發電機內的軸承，由於表面裂開及接踵而至的腐蝕疲勞所造成的早期故障，代表了一個可能導致不必要的停機與成本高昂的維修的技術問題。
- 離岸渦輪機的無障礙，存在著一個甚至更大的問題。WearSens®感測系統可以及早發現臨界操作狀態，可在發生嚴重的損壞前，即開始採取補救措施。
- 專利測量方法（專利號碼：EP 2 163 887 B1，用於測量流體及其應用的物理參數的方法與電路組件），結合低雜訊的高靈敏度與寬廣的測量範圍。
- 純油的實際導電率極低，然而，高精度WearSens®可測量低至0.1 pS/m的導電率，而且測量結果都在考量未知及變動的數量的雜質下，進行溫度補償。
- WearSens®感測器系統是與德國South Westphalia應用科學大學"策略性防腐中心"技能平台-Ing. Kuipers博士教授合作開發。
- 系統簡介：
- WearSens®是一款新式獨特的線上油品狀態監測系統。可及早提供油質變化的指示，以優化負載及/或及時進行預防性維護，其結果，可以節省巨額成本、人力工時及避免意外停機。
- 油中的變化，是軸承滾道中顆粒剪切及點蝕凹坑的預兆之一，在損壞發生之前的早期偵測，可提供潛在損傷狀態的預警。
- WearSens®從啟動的第一天開始工作，早在其它受到偵測限制的方法之前。測試已經證明，WearSens®可以偵測出標準實驗室分析結果仍報告為良好的油中變質狀態。振動及顆粒監測，只能在損壞發生後才偵測得出來。
- 能以高精度測量導電率、電應率（介電常數）及溫度。導電率及電應率（介電常數）兩者都與溫度有關，但對於任何污染物的溫度補償都是未知數，WearSens®的特色，是具有類神經網路的自適應溫度補償演算法則。
- 導電率的測量單位是pS/m，靈敏的導電率測量，可指示來自破裂的油分子的化合物的形成、微粒的存在及任何添加劑的消耗。溫度補償的數值，容許隨時進行資料的比較。
- 相對電應率即介電常數的量測。隨著添加劑用量增加時，介電常數會下降，但當全部添加劑都消耗完畢時，介電常數會再增加。結合導電率數值的考量，可以清楚看出油質的變化。
- 基於網路的分散式監測系統，極適合遠端或不易進入的地點。
- 測量結果是透過局域網路、無線局域網路或串列介面傳送。
- WearSens®的構想、開發及製造，都在德國，它代表了一種全新的油品狀態監測方式，適合各種應用。這是頭一次，油中的變化，可以採取精準的線上連續偵測方式，而偵測結果，可以優化負載、降低磨損及節省成本。
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- 範圍：
- 導電率：0.1～100,000 pS/m（可選購高範圍0.1～2.000.000 pS/m）。
- 相對電應率（介電常數）：1～5。
- 靈敏度：
- 導電率：0.01 pS/m。
- 相對電應率（介電常數）：1*10-6。
- 溫度及壓力：
- 最大的油壓：60 bar＠20℃。
- 油溫：-10℃～+70℃（高溫選購：-10～+150℃，低溫選購：-40～+ 65℃）。
- 操作溫度：-20℃～+70℃。
- 材質：
- 感測器材質：不锈鋼及鋁。
- 導線：3m遮蔽式（可選購不同的導線長度）。
- 連接：
- ¼'' Swagelok®接頭，適用於6mm外徑管子（提供選購的連接頭）。
- 通訊介面：
- 串列通訊RS232/RS232-USB (可選購LAN、GSM、Profibus、Modbus、CAN、0..10V、0/4..20mA)。
- 電氣需求：
- 115/230 VAC，50/60 Hz (可選購 +24 VDC)。
- 詳細規格、配件、軟體及選購，歡迎洽詢。
- 範圍：
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- A new approach to gearbox and bearing failure prevention, online and continuous!
- Detect change before wear damage; Early warning before damage starts
- Optimise load/reduce wear
- Timely predictive maintenance
- Prevent abrasive wear
- Detect consumption of additives
- Patented measuring method
- More sensitive than vibration monitoring, more sensitive than lab analysis
- Easy to install or retrofit
- Web based, decentralised monitoring
- Condition Based Maintenance — large cost savings
- Application Areas:
- Marine
- Heavy machinery
- Offshore Wind Turbines
- Automotive test rigs
- Mining
- Application Targets:
- Wind turbine gearboxes
- Contamination detection
- Roller bearing wear detection
- Oil deterioration monitoring
- Oil Condition monitoring solution
- System Overview:
- WearSens® is a unique, new system for online oil condition monitoring. Early indication of oil changes leads to optimum loading and/or timely preventative maintenance. The result, huge savings in money, downtime and man hours.
- Change in oil is one of the precursors of particle shearing and pitting in the bearing raceway. Early detection can warn of potential damage states, before damage occurs.
- WearSens® works from day 1, prior to other technologies limits of detection. Tests have shown that the WearSens® can detect deterioration in oil while standard laboratory analysis still reports oil as good. Vibration and particle monitoring only detect after damage is done.
- Conductivity, permittivity and temperature are measured with high precision. Both conductivity and permittivity are temperature dependent, but the temperature compensation for any pollutants is unknown. WearSens® features a self-adapting temperature compensation algorithm similar to a neural network.
- Conductivity is measured in picosiemens per metre. This sensitive conductivity measurement indicates the formation of compounds from broken oil molecules, the presence of micro particles and the consumption of any additives. The temperature compensated values allow comparison at any time.
- Relative permittivity is a measure of the dielectric constant. Permittivity decreases as additives are used up but will then increase once all additives are consumed. Taken in conjunction with the conductivity values, a clear picture emerges of the changes in the oil.
- The web based, decentralized monitoring system is perfect for remote or inaccessible locations.
- Measurements are transmitted via LAN, WLAN or the serial interface.
- Conceived, developed and manufactured in Germany the WearSens® represents a completely new approach to oil condition monitoring in a variety of applications. For the first time, changes in oil can be detected accurately, online and continuously. The result, optimised loading, reduced wear and cost savings.
- Technical Description:
- WearSens® - ideal for early fault detection, changes in the machine detected from the start - long before failure states.
- Applications：
- Wind turbines, including offshore
- Oil insulated turbines, including cogen plants
- Lubricant performance analysis
- Test benches for automotive and marine applications
- WearSens® detects early changes in the "quality of the machine" from day 1 - before damage occurs. This represents a great improvement on vibration monitoring systems, oil particle analyzers and oil filtration systems which detect after damage occurs.
- cmc Instruments together with their academic and industrial partners have a thorough understanding of how abrasive wear damage occurs. First, a very small hairline crack appears as a result of roller bearing passage. Oil enters this crack. Localized vibration and temperature rises cause the oil to degrade into oil soaps, acids and hydrogen. The hydrogen then causes embrittlement of the surrounding metal accelerating the possibility of shearing and consequent pitting of the bearing.
- Premature bearing failures in industrial gearboxes usually result from friction-induced vibration loads due to cracks in the raceway surface.
- The early detection of critical lubricant states allows preventative maintenance on the transmission - before damage occurs.
- Early failures of bearings in wind turbines due to surface cracking and subsequent corrosion fatigue represent a technical problem that can lead to unnecessary downtime and costly repairs.
- Accessibility of offshore turbines presents an even greater problem. The WearSens® sensor system can identify critical operating states early, so that corrective action can be initiated before serious damage.
- The patented measurement method (Patentnr.: EP 2 163 887 B1, Method and circuit assembly for measuring physical parameters in fluids and their application) combines a high sensitivity at a low noise with a broad measurement range.
- The electrical conductivity of oil is very low. However, it is possible to measure down to to 0.1 pS/m with the high precision WearSens®. Results are temperature compensated taking into account the unknown and varying amounts of impurities.
- The web based, decentralised monitoring system is perfect for remote or inaccessible locations. Measurements are transmitted via LAN, WLAN or the serial interface.
- The WearSens® sensor system was developed in collaboration with the Competence Platform "center for strategic corrosion protection" Prof. Dr.-Ing. Kuipers of the University of Applied Sciences, South Westphalia.
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- Ranges:
- Conductivity: 0.1 to 100,000 pS/m (optional, high range: 0.1 to 2.000.000 pS/m)
- Relative permittivity: 1 to 5
- Sensitivity:
- Conductivity: 0.1 pS/m
- Relative permittivity: 1*10-6
- Temperature and pressure:
- Max oil pressure: 60 barg at 20℃
- Oil temperature: -10℃ to +70℃ (optional, high temperature: -10° to + 150°C)(optional, low temperature: -40° to + 65°C)
- Operating temperature: -20℃ to +70℃
- Material:
- Sensor material: Stainless steel (bowl and carrier) and aluminium (head)
- Cable: 3 metre, shielded (optional, different cable length)
- Connections:
- ¼'' Swagelok® for 6mm o.d. tube (optional connectors available)
- Communication Interface:
- Serial communication via RS232/RS232-USB (opt.: LAN, GSM, Profibus, Modbus, CAN, 0..10V, 0/4..20mA)
- Electrical requirements:
- 115/230 VAC, 50/60 Hz (optional, +24 VDC)
- Please feel free to contact for detailed specifications, accessories, software and options.
- Ranges: