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GB2108273A - A process for the advance indication of breakdowns or faults in a tribological (lubrication) system - Google Patents

A process for the advance indication of breakdowns or faults in a tribological (lubrication) system Download PDF

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Publication number
GB2108273A
GB2108273A GB08224827A GB8224827A GB2108273A GB 2108273 A GB2108273 A GB 2108273A GB 08224827 A GB08224827 A GB 08224827A GB 8224827 A GB8224827 A GB 8224827A GB 2108273 A GB2108273 A GB 2108273A
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wear
values
contaminants
particle
normal
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GB2108273B (en
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Jozsef Fodor
Andrasne Balog
Judit Beke
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Autoipari Kutato Intezet
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Autoipari Kutato Intezet
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/26Oils; Viscous liquids; Paints; Inks
    • G01N33/28Oils, i.e. hydrocarbon liquids
    • G01N33/2888Lubricating oil characteristics, e.g. deterioration
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16NLUBRICATING
    • F16N29/00Special means in lubricating arrangements or systems providing for the indication or detection of undesired conditions; Use of devices responsive to conditions in lubricating arrangements or systems
    • GPHYSICS
    • G07CHECKING-DEVICES
    • G07CTIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C3/00Registering or indicating the condition or the working of machines or other apparatus, other than vehicles

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Food Science & Technology (AREA)
  • Medicinal Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Mechanical Engineering (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Analysing Materials By The Use Of Radiation (AREA)
  • Testing Of Engines (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)

Abstract

After the machinery has been run in samples are taken from the lubricant and the quantitative values of the wear products and external contaminants in normal use of the tribological system are determined and the particle number characteristics of the wear products and contaminants of this normal wear are determined. These values are then treated as the permissible values for normal operation and in an operating tribological system samples are taken periodically and analysed to monitor whether the quantity and particle size of the wear products and contaminants remain within the range of permissible values. Should the range of permissible values be exceeded a particle morphological analysis is performed and the system is classified as faulty in the presence of spherical fatigue particles and/or chip shaped particles characteristic of abrasive wear.

Description

SPECIFICATION A process for the advance indication of breakdowns or faults in a tribological (lubrication) system Our invention concerns a process for the examination and classification of a tribological (lubrication) system for the purpose of advance indication of breakdowns or faults, wherein the lubricant material of machinery in operation is periodically sampled and in dependence on the result of a rapid compar ing-monitoring analysis, the detailed tests suitable for determining the initial phase of breakdown are performed and on the basis of these tests, the tribological system is classified.
The advance indication of breakdowns of tribological systems is required by technical safety or economy reasons. Thus, in the case of aircraft power plants and hydraulic systems the technical safety reasons are the determining reasons, while in other fields, e.g. in the case of power turbines or rolling mills, the advance indication of faults or breakdowns can reduce economic losses. In nuclear power plants, the advance indication of breakdowns of power plant parts or sub-units enables the efficiency of the power plant to be improved buy a better co-ordination of the shut-downs that become necessary from time to time for maintenance.
In large-size rotary machinery employed in power plants and rolling mills, the bearings are monitored by means of instruments sensing temperature and vibration. These instruments sense and indicate the phenomena arising from faults or breakdowns, since an increase in the vibration of a rotary shaft or an increase in the temperature of a bearing is a phenomenon which arises as a consequence of a fault having already occurred and thus the indication or display of the fault assists in avoiding a complete destruction or more serious damage to the bearings.
These methods cannot therefore be regarded as suitable for the advance indication of faults or breakdowns becuase they do not indicate or warn of the initial phase of the development of faults or breakdowns.
An advance indication of faults or breakdowns of tribological systems can only be obtained by a knowledge of the state of wear of the system, because a regular intermittent or continuous monitoring of the state of wear enables the wear phenomena leading to faults or breakdowns to be recognised and thus the probability of breakdowns occurring can be determined. For this purpose, it is necessary to determine the qualitative and quantitative parameters of the process of wear arising in the proper use of the tribological system and based on that a breakdown can be indicated in advance by the periodic or continuous monitoring of the state of wear of the system.
Tribological systems exhibit characteristic wear processes as a function of the operational time. One characteristic of the process of wear is the amount of material that has detached or flaked off from the surfaces subjected to wear while another characteristic is the shape of the detached material particles, the shape changing in the various phases of the wear process. The wear process is illustrated in Figure 1 where a function of operational time, the amount G of material that has been detached is shown.
In Figure 1,1 designates the running-in phase where both abrasive and adhesive wear arise together, II designates the adhesive wear phase, i.e.
the practical lifetime phase with virtually constant rate of wear, and Ill is the phase of rapid increase in wear, wherein the system is at the limit of its operational life, imminent breakdown can be ex pected and its characteristic is the appearance of abrasive wear and/or surface fatigue wear. In addition to the quantitative parameters the removed particles appearing in the wear process also provide a very characteristic picture as regards their shape and dimensions. The dimensions of the particles arising in the course of adhesive wear amount to up to 30 lim, are of platelet shape, while the particles from the abrasive wear phase are characteristically of spiral chip form with large longitudinal dimensions; in the phase of surface fatigue wear, one encounters spherical shapes and large-sized particles.The illustrated wear process may be modified by abrasive contaminants originating from the environment and passing into the system during operation. Their effect depends on the quantity and quality of the abrasive wear materials entering into the system and these may also initiate a rapid wear process that is characteristic of phase Ill, but in this case it may still be possible to return or revert to the wear values characteristic of phase II.
There are many methods of determining the qualitative and quantitative characteristics of wear from examining the detached material particles or the lubricant containing the products of wear. The composition as regards the elements present in the wear product, i.e. metals alloys and contaminants, may also be determined by direct analysis from a sample of lubricant. These methods are usually automated. Such methods include the spectrometric and spectrophotometric methods. However, it is a common drawback of these methods that they cannot measure particles with a size exceeding 5 Mm and thus the values obtained with these methods are not quantitative and are only suitable for following the quantitative changes in the process of wear to a limited extent.Thus, for instance, the wear values as determined by atomic absorption spectrophotometry are sometimes smaller by order of magnitude than the values obtained by neutron activation techniques, and the situation is similar for other direct spectrometric processes also. Thus on the basis of the above, the direct spectrometric methods are unsuitable for the analysis of the large-sized particles that are characteristic to the dangerous phase of the wear process. The gamma spectrometric test method which monitors the neutron activity of the wear products is highly suitable for the quantitative determination of the wear process and is reliable but its performance requires a great deal of time and is therefore unsuitable for the indication of rapid breakdowns.The onset of wear phase Ill can be detected by the dimensional changes in the wear particles and for the rapid examination or testing of this phase of wear automatic particle-classifying and particle-counting devices are available. These devices offer rapid indications from lubricant samples of the concentration and size distribution of the wear particles and of the changes in these parameters.
However, the change in concentration of dimensions in the particles may originate from an external source, e.g. from the original contamination of "fresh" lubricant, or from the topping-up of oil. Thus even this method does not provideperse unambiguous data concerning the onset of wear phase Ill.
More complete information may be obtained if the lubricant applied to the system is previously classified or if by suitable filtering, the suitable lubricant of constant purity is assured for the system.
Figure 2 illustrates the performance and suitability of the known methods of examining wear for the analysis of wear particles and contaminant particles of varying size distributions. The particle size M is indicated in Fm and band a corresponds to ferrographic methods, band b corresponds to particleclassifying counting, band c corresponds to the neutron activation method, band dcorrespondsto spectroscopic methods utilising chemical preparation, and band e corresponds to direct spectroscopic methods.
The aim of our invention was the provision of a suitable and reliable examining and monitoring method for recognising in a rapid and reliable manner the onset of wear phase Ill to provide advance indication of breakdowns. The individual examining or testing processes as mentioned above are not suitable for this by themselves. The rapid spectrometric methods providing direct analysis from the lubricant oil are not suitable for advance indications of breakdowns in tribological systems because they cannot determine, or operate with, the large sized wear particles characteristic of the initial phase of breakdown. The neutron activation technique or any other analytical method performing a similar sample processing would be suitable but cannot meet the demands for rapidity of the tests.
The automatic particle-classifying and counting methods are rapid but evaluating the results the changes due to contamination introduced from the lubricant system or from the environment must also be taken into account. Thus a larger sized particle of quartz introduced from the environment or some other contaminant particle, which is to be measured or detected as a change, does not necessarily indicate that the process of wear has accelerated. It is therefore important to find out in the case of large-sized particles whether they originate from the surface subject to wear. Ferrographic methods seem very suitable for this purpose and with ferrographic means the wear particle shapes can be well identified in order to characterise the individual phases of the wear process.Naturally, in selecting methods of test, a further consideration that must be taken into account is whether the testing can be performed on site in a rapid manner. The aim of the present invention is sought to be realised by recognising that the process of wear is influenced by ambient effects and in certain cases may even determine that process. Thus, in addition to monitoring the process of wear there is also a need for measuring the ambient effects. Hence we also determine the characteristic wear data and contamination levels which also show up the ambient effects and which are associated with the normal wear process, and in cases which appear critical the particles are subjected to a morphological analysis.After determining the wear values of the normal wear process and the associated values of the ambient effects, the monitoring of whether the wear process is normal is simple and rapid and is a routine task not requiring expertise. At the critical values the morphological analysis ofthe particles provides an unambiguous indication of the onset of breakdowns. The monitoring of wear to be performed most frequently and over a long time, i.e. over the lifetime of the mechanical construction, is rapid and does not burden the operation with tests which require a lot of time and expertise. The monitoring or testing task requiring high expertise and care arises only very infrequently and thus the system of advance indication of breakdowns is economical.
Our invention concerns a process for the examination and classification of the state of wear of a tribological system for the purpose of advance indication of faults or breakdowns, wherein the products of wear and contaminants present in the lubricant are qualitatively and quantitatively examined, and after the running-in phase the quantitative values of the wear product and contaminants characteristic of the normal operation of the tribological system are determined by means of a gammaspectrometric sampling method which is based on the neutron activity of the wear products and the contaminants or by another method which is equivalent with this as regards accuracy and sensitivity, these quantitative values are classified or regarded as normal wear values and the particle number characteristics of the wear products and contaminants of this normal wear are determined expediently by means of an automatic particle-classifying counter, these particle number characteristics are classified as the normal wear characteristics of the system, and are the permitted values for normal operation of the system, then for the monitoring of the operational tribological system lubricant samples are taken expediently at predetermined intervals and samples are analysed by means of an automatic particle-classifying counter; should the particle number values exceed the permissible characteristics of normal wear then the sample is subjected to a morphological analysis of particles by means of a ferrograph, and is classified as faulty or prone to breakdown in the presence of additional particles of spherical shape or chip form characteristic of abrasive wear. The process according to our invention is suitable for industrial use without a significant increase in operational costs by virtue of the fact that the most frequently performed longterm wear monitoring i.e. during the complete of full lifetime of the system, can be performed rapidly without requiring special skills. Tests involving special skills and expertise and care are required in exceptional cases only.The aforementioned most frequently performed step of the process according to the invention assures the detection of the entry of external contaminants and ambient effects which can greatly accelerate the process of wear and can cause serious damage in a short time. -The invention is described in detail by way of a preferred embodi ment set forth below.
By employing a neutron activation technique assuring high accuray the wear values associated with phase II in Figure 1 are determined for the lubricants of several driving mechanisms of the same type. The identification of phase II is carried out by taking periodically lubricant oil samples several times consecutively and from them the quantity of the elements characteristic of the main wear pairs and the quantity of contaminants originating externally of the mechanism are determined.
The rate of wear of the elements characteristic of the wear of the constructional materials is constant in phase II if the amount of external contaminants is unchanged. In the case of varying contaminant quantities in the sample, regard should be had only to the quantities of constructional material related to the same or constant amount of contaminant. This is because an increase in the quantity of contaminants causes an increase in the amount of wear particles originating from the constructional material. The results of wear of the examination phase as described above will be the same for tribological systems of the same type and dimensions, e.g. for the same type of aircraft power plant.
In addition to the above test, the lubricant samples of the test or examination phase are also subjected to contamination analysis by means of a particleclassifying counter. The results ofthe analysis are categorised in accordance with ISOiTC 131/Sc-6.
This categorisation takes place on the basis of the number of particles below 5Fm and above 50m in one ml of sample. The categories are designated with numbers.
Naturally in this test, in the case of varying amounts of contaminants, the amounts of constructional material to be taken into account must be related to the same or constant amounts of contaminant.
The two tests or examinations provide the following data: the measurement with a neutron activation method provides wear values expressed in g characteristic of the wear in the wear phases II, and the associated contaminant quantities are also expressed in g; while from the data of the particle counter contamination values are obtained which are expressed by the category numbers according to the ISO code and characteristic of phase II of the tribological system. While the previous wear value expressed in g is characteristic of the tribological system, the quantity of contaminants expressed in g and the contamination value expressed according to the ISO code normally also indicates the quality of the operation or running of the power plant.The simultaneous knowledge of the two values and the co-ordination thereto of the contamination value are required for phase II of the wear process because the measurement with the particle-classifying counter is very rapid and does not require special skills, and thus a high number of samples can be monitored and a single apparatus can analyse the samples of monitoring locations the number of which may even reach several hundreds. The duration of the mea surementis 1-2 minutes. Under normal operational conditions in Hungary, for aircraft power plants (gas turbines) and for hydraulic systems, we have obtained value of 13/10-18/15 according to the ISO code categories for phase 11 of the process of wear under normal conditions of wear and on the basis of several hundred samples.
When the contamination value exceeds the values just mentioned, the oil sample is subjected to ferrographic analysis. In the course offerrographic analysis, the morphological analysis of the particles allow one to determine whether the exceeding of an ISO code category that is characteristic of normal wear represents or is the consequence of the presence of abrasive particles or surface fatigue wear particles of large size which would indicate for some constructional element wear of the type shown in phase Ill and of the commencement of seizing up. In this case, further running of the system or machinery is ndt recommended because of the immenent breakdown.In addition to the result of morphological analysis, the ferrographic analysis also enables one to determine which constructional element, e.g. shaft pin or spindle or bearing surfaces are the sources of the wear particles of "dangerous" size and thus useful information is obtained for repairing the system.
The result of the ferrographic analysis may show that the exceeding of the ISO code category characteristic of normal wear is the result of an environmental or ambient effect. The increase in particle number and size is of external origin. In this case, it is necessary to wash and purify the system and to re-monitor it, following the purification.
The above-described example has been successfully tried out in practice for aircraft gas turbines and for hydraulic systems, for the lubrication systems of rolling mills and for the hydraulic systems of machine tools.
In the surveying stage of the monitoring system for the advance indication of breakdowns, the determination of the normal wear values and the contamination values requires a great deal of time but on the other hand during normal operation the contamination analysis to be performed with an automatic particle-classifier and counter is very quick. In this way, the regular monitoring oftribological systems of high value becomes possible, as does the rapid detection of changes in the normal process of wear.
The ferrographic analysis of samples classified as critical renders it probable that breakdowns are accurately identified and provides indications for repair by indicating the source of the surface of the constructional part from which wear particles of excessive size originate; or it may be determined that the change is the result of an external effect which can then by suitable intervention e.g.
washing, be terminated and after repeated tests the system may continue in operation.

Claims (3)

1. A process for the examination and classification of the state of wear of a tribological system for the advance indicate n of breakdown or faults, wherein the products of wear and external contaminants present in the lubricant are examined quantitatively and qualitatively, characterised in that after running-in, the quantitative values of wear products and contaminants characteristic of the normal operation ofthetribological system are determined buy a gamma-spectrometric sampling method based on the neutron activity of the wear products and contaminants or by another method of equal accuracy and sensitivity and these quantitative values are characterised as normal wear values, then the particle number characteristics of the wear products and contaminants of this normal wear are determined, preferably by means of an automatic particleclassifying counter, these particle number characteristics are taken to be the normal wear characteristics of the system and are classified as the permissible values for normal operation of the system, then for monitoring the operation of tribological systems lubricant samples are taken, expediently at predetermined intervals and the samples - are analysed by means of an automatic particle-classifying counter, and in cases where the particle numbervalues exceed the values characteristic of the permissible normal wear the sample is submitted to a particle morphological analysis, and the system is classified as faulty and prone to breakdown when the presence of spherical fatigue particles and/or chip shaped particles characteristic of abrasive wear are detected.
2. A process according to claim 1, characterised in that when the system is designated as faulty or prone to breakdown due to the presence of contaminants of external origin the lubricant and the system are decontaminated and the system is then classified as suitable for a test run.
3. A process according to claim 1 or claim 2 substantially as herein particularly described.
GB08224827A 1981-09-09 1982-08-31 A process for the advance indication of breakdowns or faults in a tribological (lubrication) system Expired GB2108273B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
HU261181A HU183572B (en) 1981-09-09 1981-09-09 Method for testing the abrasion state of tribology system

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GB2108273A true GB2108273A (en) 1983-05-11
GB2108273B GB2108273B (en) 1985-07-03

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JP (1) JPS5886432A (en)
DE (1) DE3232132A1 (en)
FR (1) FR2513412A1 (en)
GB (1) GB2108273B (en)
HU (1) HU183572B (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2171211A (en) * 1985-02-19 1986-08-20 Coal Ind Monitoring the operational condition of mechanical equipment
EP1229287A1 (en) * 2001-01-24 2002-08-07 Union Key S.r.l. System and method for monitoring and managing data related to motor machines
RU2245537C2 (en) * 2003-03-24 2005-01-27 Омский государственный университет путей сообщения Method of inspecting wear of engine parts
RU2322660C2 (en) * 2006-05-16 2008-04-20 Государственное образовательное учреждение высшего профессионального образования "Южно-Российский государственный технический университет (Новочеркасский политехнический институт)", ГОУ ВПО ЮРГТУ (НПИ) Mode of control of wearing of tube systems of mechanisms and machines using technological liquids
RU2413200C1 (en) * 2009-06-30 2011-02-27 Государственное образовательное учреждение высшего профессионального образования "Южно-Российский государственный технический университет (Новочеркасский политехнический институт)" Procedure for continuous control over technical condition of local tribo-unit opearing in flow of process liquid
CN110426194A (en) * 2019-08-23 2019-11-08 中国兵器科学研究院 Consider the mechanical part life test method of abrasion and fatigue interaction
CN112747925A (en) * 2020-12-28 2021-05-04 西南交通大学 Rolling bearing fault diagnosis method based on composite morphological filtering

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CN1010130B (en) * 1985-06-21 1990-10-24 美国通用电气公司 Method for Determining the Spent Life of Turbine Components
US5042295A (en) * 1985-06-21 1991-08-27 General Electric Company Method for determining remaining useful life of turbine components
US5110429A (en) * 1988-12-30 1992-05-05 Jzd Valassko Se Sidlem Ve Vlachovicich Method and arrangement for diagnostics of friction systems of motors
WO1993003458A1 (en) * 1991-08-09 1993-02-18 Predictive Maintenance Corporation Method and apparatus for monitoring equipment
DE102007044104B3 (en) * 2007-09-15 2009-04-16 Wehner, Karsten, Prof. Dr. Piston engine's i.e. ship diesel engine, tribological system monitoring method, involves assigning signal level to components of piston and correlating with signals, such that tribological operation condition of system is detected
CN105181338A (en) * 2015-09-08 2015-12-23 广西大学 Engine state monitoring and fault diagnosis method based on vibration and fluid information
US12019059B2 (en) 2020-10-16 2024-06-25 Saudi Arabian Oil Company Detecting equipment defects using lubricant analysis

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US2818766A (en) * 1955-07-11 1958-01-07 Baird Associates Inc Method for oil analysis
FR1500048A (en) * 1966-06-15 1967-11-03 Commissariat Energie Atomique Lubricant marking process
US3526127A (en) * 1969-03-24 1970-09-01 Mobil Oil Corp Engine oil analysis system
AU498574B2 (en) * 1974-06-13 1979-03-15 Mobil Oil Australia Limited Determining wear
US4176545A (en) * 1978-06-16 1979-12-04 Oddo Luigi G Electronic engine wear detector
GB2040739B (en) * 1979-02-01 1982-11-17 Technical Dev Co Apparatus for removing entrapped gas and separating out particles from fluid
US4238197A (en) * 1979-04-12 1980-12-09 The United States Of America As Represented By The Secretary Of The Air Force Analysis of lubricating oils for iron content

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2171211A (en) * 1985-02-19 1986-08-20 Coal Ind Monitoring the operational condition of mechanical equipment
EP1229287A1 (en) * 2001-01-24 2002-08-07 Union Key S.r.l. System and method for monitoring and managing data related to motor machines
RU2245537C2 (en) * 2003-03-24 2005-01-27 Омский государственный университет путей сообщения Method of inspecting wear of engine parts
RU2322660C2 (en) * 2006-05-16 2008-04-20 Государственное образовательное учреждение высшего профессионального образования "Южно-Российский государственный технический университет (Новочеркасский политехнический институт)", ГОУ ВПО ЮРГТУ (НПИ) Mode of control of wearing of tube systems of mechanisms and machines using technological liquids
RU2413200C1 (en) * 2009-06-30 2011-02-27 Государственное образовательное учреждение высшего профессионального образования "Южно-Российский государственный технический университет (Новочеркасский политехнический институт)" Procedure for continuous control over technical condition of local tribo-unit opearing in flow of process liquid
CN110426194A (en) * 2019-08-23 2019-11-08 中国兵器科学研究院 Consider the mechanical part life test method of abrasion and fatigue interaction
CN110426194B (en) * 2019-08-23 2020-12-25 中国兵器科学研究院 Mechanical part life test method considering abrasion and fatigue interaction
CN112747925A (en) * 2020-12-28 2021-05-04 西南交通大学 Rolling bearing fault diagnosis method based on composite morphological filtering

Also Published As

Publication number Publication date
HU183572B (en) 1984-05-28
JPS5886432A (en) 1983-05-24
GB2108273B (en) 1985-07-03
FR2513412A1 (en) 1983-03-25
DE3232132A1 (en) 1983-03-24

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