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Defence Machinery Reliability:Condition Monitoring Research at DST
Dr Andrew Becker (Aerospace Division) Dr James Harris (Maritime Division)
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DST’s role in this space Link between CM and reliability Oil & Wear Debris Analysis WDA Novel Sensors:
– Research– Lab Testing– Field Testing
A Final Thought
Overview
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Provide support for immediate and significant ADF issues
Investigate emerging technology to enhance system RAM
Conduct research into new techniques for potential future applications
DST’s Role
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RAM & CBM relies on understanding the systems condition
Condition Monitoring (CM) a key enabler
Fundamental to informed maintenance & operational decision making
Oil analysis is one aspect of CM – when done correctly it can be very valuable
Limits Limits Limits
Link between CM & Reliability
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Oil Condition & Wear Debris AnalysisOil Analysis
Oil Condition(Physical and
Chemical condition of the fluid)
Wear Debris(Entrained solid
particulate)
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Wear Debris Analysis (WDA)
Elemental Composition
Size / Count
Morphology• Shape• Colour• Edge detail• Surface features
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WDA Example 1: Safety Ferrous debris recovered from gearbox magnetic chip detector Composition: bearing material Morphology: rolling contact fatigue History of ↑ debris quantity Aircraft poised for imminent deployment to sea Outcome: Alternative aircraft deployed & gearbox replaced
Example of bearing debris recovered
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WDA Example 2: Savings/Availability
Debris recovered from engine magnetic chip detector Found to be benign alloy (i.e. not bearing or gear) Outcome: Engine remained in service Saved availability, maintenance time and significant $$$
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Laser
Spectrometer
Laser Induced Breakdown Spectroscopy (LIBS)
Portable X-ray Fluorescence (XRF)
DST: WDA In-Field
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What is commercially available beyond the traditional metrics (temp., pressure, vibration)? Could it be applied to Diesel engines (still the mainstay of power generation) Could have wider applications (e.g. Pod bearing lube systems)
Novel Sensor Research
Image: www.Riskcom.global
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Sensor Description
Wear Debris
Dielectric
Density
Viscosity
% H
2 O
Temperature
Kittiwake Oil Condition X XKittiwake Moisture X XMeasurement – Specialities Fluid Property Analyser X X X X
Tan Delta Oil Quality XEaton – Internormen IVS 01 X X XSengenuity Viscosity X XGastops Metalscan X
Novel Sensor Research
Reports:(DSTG-CR-2016-0119)(DSTO-CR-2015-0105)(DST-Group-CR-2017-0189)
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Novel Sensor Research - Lab
Heated and agitated oil
Sensors mounted into housing
Rotary Stirrer
Heater
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0
20
40
60
80
100
120
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0 5000 10000 15000 20000 25000 30000 35000
Vis
cosi
ty S
enso
r ou
tpu
t
Time (s)
IVS Viscosity
Measure Spec Viscosity
Sengenuity Viscosity
Addition of 3% vol. tap water
Measure Spec. viscosity unstable outside of its specified viscosity
Measure Spec. viscosity noisy at emulsion formation
Sengenuity viscosity
IVS viscosity
Non-linearity
Stability
Also:
• Linearity
• Sensitivity
Novel Sensor Research – Lab
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0 1000100 200 300 400 500 600 700 800 900microns (1mm)
SOA Maximum particle detection 10 μm (at best)
Inductive Debris Sensor detection range 100 to 1000+ μm
Applicable to any reticulated lube oil system where >100um ferrous wear debris is likely
Wear Debris Sensing
Significant improvement to traditional debris detection
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0
500
1000
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0 10 20 30 40 50 60 70 80 90Test Hours
Ferro
mag
netic
Par
ticle
Cou
nt
0
200
400
600
800
1000
Ferro
mag
netic
Par
ticle
Gen
erat
ion
Rat
e[c
ount
s/hr
]
Counts Rate
Novel Sensor Research - Lab
DST test of Bell 206 helicopter gearbox test of planetary gear bearing
Inner raceway
Gearbox test rig showing sensor
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Hedemora V18B – ASC Osborn DGTF
Novel Sensor Research - Field• Applied to a submarine diesel engines at run-in• Rapid thermal and condition cycling PLUS wear debris
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0
200
400
600
800
0:00:00 5:00:00 10:00:00 15:00:00 20:00:00
Ferr
ous D
ebri
s (m
g)
Run Time (hrs)
Fe Debris for 3/4" Sensor - All Engines
Collins DE3 Collins DE2 Collins DE1 Farncomb DE3 Farncomb DE2
2 hrs
Real Time Debris Plots
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Figure 1: Runs 1 -3 Collins DE1 (843) - sample of debris extracted using 60 µm filter patch with
typical constituents identified
Fe debris
glass bead
cloth lint
grinding debris
What the debris looks like:
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For the Future:
Fitting of sensors to existing equipment
DST can help but a limited resource
Questions?
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