Early detection of gear damage reduces downtime and repair costs
Knowing early when bearings or gearing parts are failing, not only ensures a continuous operating process but also reduces repair costs.
MetalSCAN is a highly efficient tool for achieving this goal with low investment and without expensive analyses (current costs).
The MetalSCAN system consists of an inductive sensor and an alarm module (optional) which can be omitted when integrating the sensor signal into existing monitoring or control systems (e.g. vibration-based CMS, system control).
Due to the design of sensor, adapted to the SAE flange form (see attached data sheets), the installation of the sensor, by part of customer, into the return flow of the lubricating oil circuit (e.g. directly upstream of the pump) is easily possible. If required, we can also install the sensor for you.
The selection of sensor (8/25/38mm) is essentially determined by the minimum flow rate of oil (see minimum flow rate required in the MetalSCAN Flyer). In principle, the sensor diameter should be as small as possible, but nevertheless large enough so that no impermissible back pressure occurs in front of the sensor.
In contrast to the known optical particle counters, the sensor counts only the metallic particles in the lubricating oil and can also be used in contaminated/turbid oil. Impurities in the oil such as water, soot, plastics etc. as well as air bubbles do not affect the analysis.
As the system does not require any reference values for detecting a damage, it can also be used with pre-damaged gearboxes for damage tracking. Worldwide, more than 10,000 sensors are used successfully in the aerospace, the gas turbine technology as well as in industrial, marine and wind power gearboxes. All sensors are self-monitoring (sensor error, cable break) as well as maintenance- and recalibration- free. Our All-in-One MetalSCAN units are equipped with sensor, bypass filter and communication unit and can therefore be used immediately and independently.
Also there are possible the external monitoring of the trends as well as the visualization of particle development via Internet (to be called password-protected via standard web browser).
The MetalSCAN principle:
Any damage to gearbox produces metallic abrasion already at early stage. As the number of metal particles per unit time correlates with the size of damage, any developing damage and its further development are recognized without any doubt. Even damages to planetary bearings and slowly rotating bearings, difficult/late or not to be monitored with other methods, are detected early and reliably.
The evaluation impresses with its simplicity:
If the sensor does not count excessive numbers of particles, there is no damage to the gearbox! When counting increased values, there is no doubt that there is an incipient damage! The number of metal particles correlates with the damage. Therefore, the damage development can be traced without further diagnoses. Reference data are not required. Consequently, the subsequent installation is possible at any time, even on already pre-damaged gearboxes.
The optional alarm module can be installed anywhere (up to 100 m away from the sensor) and has a graphic display for clear text indication of:
– number of the scanned metal particles
– operating condition
– graphic trend display
Furthermore, the alarm module is equipped with indicator lights for displaying when warning limits have been exceeded as well as with various digital outputs which can be assigned according to customer requirements. If required, several sensors can be connected to an appropriately prepared alarm module.
The MetalSCAN sensors can also be connected directly to existing control/monitoring systems. Please ask for the electrical connection diagram. We are pleased to send you the same in advance.
With pleasure we are at your disposal for any questions you may have, in particular regarding the selection and installation of the sensor as well as the connection to existing plant control systems.