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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

140

160

180

200

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

1500

2000

2500

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?