Hydraulic Fluid Ageing Determination via Thermal Simulation
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Solution Overview
Problem
Current methods fail to provide a reliable and efficient means to determine the quality and state of ageing of hydraulic fluids in aircraft systems between maintenance procedures, leading to potential system failures due to unknown fluid degradation.
Innovation Solution
A device comprising an ageing determination unit and a temperature determination unit that calculates the overall ageing of hydraulic fluids by assessing discrete fluid volumes and their temperatures within the system, using numerical thermal simulation and temperature sensors to monitor and predict fluid degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic fluid is monitored only during maintenance procedures, then maintenance costs are reduced, but system reliability deteriorates due to unknown fluid degradation between checks
Solution Approach 1:
The system performs preliminary monitoring and assessment of hydraulic fluid ageing continuously between maintenance procedures. Temperature determination devices and ageing calculation units proactively track fluid degradation before critical failure occurs, enabling early intervention and extending effective service life without requiring more frequent maintenance stops.
Solution Approach 2:
The system establishes continuous feedback loops by monitoring temperature data and calculating ageing factors in real-time. This feedback mechanism provides ongoing information about fluid condition, allowing operators to make informed decisions about maintenance timing and extend service intervals based on actual fluid state rather than fixed schedules.
2Productivity
If hydraulic fluid is replaced based on fixed service intervals, then maintenance simplicity is maintained, but resource efficiency deteriorates due to premature or delayed replacement
Solution Approach 1:
The system transitions from static, fixed-interval replacement schedules to dynamic, condition-based maintenance. Ageing determination devices continuously assess actual fluid degradation state, allowing maintenance intervals to adapt dynamically to real-time conditions. This optimizes resource efficiency by replacing fluid based on actual need rather than arbitrary time thresholds.
Solution Approach 2:
The system monitors changes in critical parameters such as temperature and calculated ageing factors to determine optimal replacement timing. By tracking parameter evolution and comparing against threshold values, the system maintains simplicity through automated decision-making while improving resource efficiency through data-driven replacement scheduling.
3Measurement precision
If temperature monitoring is implemented throughout the hydraulic system, then ageing determination accuracy is improved, but device complexity increases
Solution Approach 1:
The hydraulic system is divided into discrete monitored zones with temperature determination devices positioned at strategically selected locations. Rather than continuous monitoring throughout, the system segments the fluid path into representative sections, measuring temperature at key points and using these discrete measurements to calculate overall ageing. This reduces device complexity while maintaining sufficient accuracy for maintenance decisions.
Solution Approach 2:
The system introduces an intermediary calculation layer that processes temperature data from multiple sensors and synthesizes overall ageing information. The ageing determination device acts as an intermediary, aggregating data from distributed temperature sensors and computing composite ageing factors that represent the entire hydraulic fluid condition, simplifying the interface between complex sensing and simple decision-making.
Data Source
AI summary
A device for determining ageing of a hydraulic fluid in a hydraulic system with a multitude of hydraulic components is provided. The device comprises at least one temperature determination device and at least one ageing determination device, wherein the temperature determination device determines the respective temperature of each discrete fluid volume of the hydraulic fluid in the hydraulic system, and from the aforesaid the ageing determination device determines an increase in ageing. Generally, the temperature determination device carries out a numerical thermal simulation of the hydraulic system, component by component, including determining at least one temperature of at least one hydraulic component of the hydraulic system, which simulation is supported by measuring the temperatures of individual hydraulic components by means of temperature sensors.