Lubricating Oil Diagnosis After Bubble Settling in Rotary Machines
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Solution Overview
Problem
Current lubricating oil diagnosis techniques for rotary machines, such as wind power generators, face challenges in accurately measuring the state of lubricating oil due to air bubbles, which interfere with sensor data, particularly in high-viscosity oils, leading to unreliable predictive maintenance and increased downtime and costs.
Innovation Solution
A diagnosis system that includes a lubricating oil tank, a circulation line, and a chromaticity sensor to measure the lubricating oil characteristics after the machine has stopped, allowing for accurate data acquisition and analysis by reducing the influence of air bubbles, enabling real-time monitoring and predictive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine operates continuously to maintain productivity, then productivity is improved, but air bubbles are generated in the lubricating oil causing measurement errors
Solution Approach 1:
The system performs measurement preparation by stopping the machine before taking sensor readings. This preliminary action removes air bubbles from the lubricating oil, ensuring that measurements are taken under optimal conditions without continuous operation interference
Solution Approach 2:
The system implements periodic measurement cycles where the machine stops temporarily to allow air bubble separation, then resumes operation. This periodic stopping and measuring approach balances productivity maintenance with measurement accuracy requirements
2Measurement precision
If the machine is stopped frequently to measure lubricating oil state, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The system applies partial stopping action - the machine stops only long enough for air bubbles to separate from the lubricating oil, not for extended periods. This minimal interruption achieves sufficient measurement precision while minimizing productivity loss
Solution Approach 2:
The system uses sensor data to monitor lubricating oil state and provides feedback on when measurements are reliable. This feedback mechanism helps optimize the timing and duration of stoppages to balance measurement needs with productivity maintenance
3Reliability
If high-viscosity lubricating oil is used to maintain lubrication performance, then lubrication performance is improved, but air bubbles are more likely to be generated and measurement accuracy deteriorates
Solution Approach 1:
Before taking measurements of high-viscosity lubricating oil, the system stops the machine to allow air bubbles to separate. This preliminary action addresses the specific problem that high-viscosity oil retains air bubbles more strongly, ensuring measurement accuracy is not compromised by the oil's viscosity characteristics
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach provides reliable and accurate diagnosis of lubricating oil conditions, reducing downtime and maintenance costs by distinguishing between additive consumption and contamination, allowing for timely replacement and preventing failures in wind power generators.
Implementation Method 1
a chromaticity sensor that measures characteristics of the lubricating oil
Implementation Method 2
the light is scattered at an interface between the lubricating oil as a liquid and the air bubbles
Data Source
AI summary
Provided is a diagnosis technique with high reliability when a state of lubricating oil of a rotary machine such as a wind power generator is diagnosed by a state monitoring sensor. A diagnosis system of lubricating oil includes a lubricating oil utilization device, a lubricating oil tank for storing lubricating oil to be supplied to the lubricating oil utilization device, and a sensor which measures characteristics of the lubricating oil. In this system, the state of the lubricating oil is diagnosed by using sensor data obtained after a time required for air bubbles in the lubricating oil generated at the time of use of the device disappear elapses since the lubricating oil utilization device is regularly or irregularly stopped.