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http://www.machinerylubrication.com/Articles/Print/670
Ultrasonic technology (UT) has become widely accepted for the detection of leaks in both pressurized and nonpressurized systems. Most compressor service companies and several manufacturers own some type of ultrasonic sensor for pinpointing leaks. It is easy to cost-justify the purchase of an ultrasonic sensor based upon the high cost of energy loss due to leaks. However, there is another application for ultrasound that consumers, nondestructive testing (NDT) organizations, and even developers and manufacturers of ultrasonic sensors are often not aware of or overlook. UT can be used as a means to detect early wear of components such as bearings and gears due to lack of lubrication or overlubrication.
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http://www.machinerylubrication.com/Articles/Print/670
Improvements to ultrasonic sensors in the past couple years have enabled organizations to expand their monitoring practices. Increased sensitivity allows todays sensors to detect smaller signals. This enables the user to detect smaller flaws and detect them even earlier. Small pieces of grit in lubrication, for example, will be detected by the sound of impact against the rollers of a bearing. Better selectivity helps diminish ambient noise or decrease white noise. Analysis and quantification is made easier when the source signal of a bearing being monitored can be distinguished from nearby components. Also, once white noise is diminished, the quality of the signal is improved and is better served for analysis. As a bearing begins to wear or lubrication becomes less effective, the ultrasonic signature will increase in amplitude and flaws will become apparent.
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of a bearing or a piece of grit in the lubricant. As a bearing or gear rotates, the scratch or piece of grit produces impact that is detectable only in the ultrasonic range. Furthermore, the wave produced in the 40 kilohertz range does not travel far from the source. Therefore, when listening to a bearing in contact mode, sounds from other nearby components do not interfere. This prevents misdiagnosis and provides the ability to quickly pinpoint the real problem. In one such case, a United States Navy ship participated in a series of onboard tests with ultrasonic technology to evaluate the potential benefit of its implementation in several areas. During the tests, the crew from another ship asked about the ability of the technology to identify internal pump problems. The electric main lube oil pumps were not putting out sufficient pressure. The ship was fast approaching a deployment, and the crew could not determine the root cause of the loss of pressure for the pumps with other technologies. The CTRL UL101 ultrasonic inspection system and SoundCTRL were used to test the pumps. Of the four pumps, it was discovered that one of the pumps was bad, producing an abnormal amount of ultrasound, and another was suspect. The pumps were dismantled and opened, and inspection revealed that one pump had damaged components and the other pump was binding.
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Warning signs of problems relating to lubrication can be subtle but critical. Lubricant is used to decrease friction of components. If a component is underlubricated, the level of friction and sound will increase. If the component is overlubricated, there will be little-to-no sound produced at all. Such subtle changes will be detected only with a sensitive sensor with a large signal-to-noise ratio (SNR). Every electrical component produces some small amount of noise when working. The sensor should be able to distinguish this white noise from the input signal. If there is too much white noise, analysis is not possible. Additionally, too much white noise can dampen the input signal, making it undetectable. It is important to make sure the test system is adequate for the applications before it is purchased.
Figure 1. Normal Running Bearing If a bearing is damaged, intermittent pops or grating may be heard, depending on the rotation of the bearing and the degree of damage. Analysis system software will reflect a heightened crackle count, and abnormal spikes in the waveform will be visible (Figure 2).
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Figure 2. Damaged Bearing If a bearing is underlubricated, there will be an increased sound of friction. The sound intensity of the bearing will increase, and it will emit an intense scraping sound. The root mean squared (RMS) value of the signal will also increase, and the height of the waveform will visibly increase (Figure 3).
Figure 3. Underlubricated Bearing Finally, the technicians recordings and notes should be reviewed. Ultrasound is instantaneous; with the right sensor, an experienced technician will detect lubrication problems right away. The latest changes in ultrasonic sensors will further enhance the users ability. The most effective program will also consist of comparing record history for critical components obtained from several different technologies and programs including oil analysis, ultrasound and preventive maintenance. Once properly implemented, ultrasonic technology will decrease the costs of maintenance and production, increase safety standards, and increase quality control. In other words, your organization will run a lot smoother. Editors Note Benjamin Fried is employed by CTRL Systems in the product development and support division. For more information about ultrasonic technology and turnkey implementation, contact CTRL Systems at 877-287-5797. Additional resources such as test techniques, frequently asked questions and multimedia clips that demonstrate the characteristics of various component conditions are available at www.ctrlsys.com.
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