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Effective monitoring of contamination levels with OPCom FerroS particle monitors

As part of its comprehensive product range in the field of fluid technology, ARGO-HYTOS offers its customers high-performance OPCom FerroS particle monitors. The components enable precise and continuous monitoring of contamination levels in hydraulic systems. The innovative wear sensors ensure that operational reliability is maintained and can significantly increase the efficiency of machines.

By detecting and analyzing wear particles in real time, machine failures can be prevented at an early stage and the service life of components can be extended. The use of OPCom FerroS particle monitors is particularly important in applications such as ball screw drives and other heavily loaded systems.

The sensors are a cost-effective solution for wear monitoring and help to reduce operating and follow-up costs. In this article, you will learn everything you need to know about the functionality and benefits of OPCom FerroS particle monitors from ARGO-HYTOS. We will also tell you how you can contribute to the optimization of your machines.

The functional principle of OPCom FerroS particle monitors

The OPCom FerroS particle monitors from ARGO-HYTOS are advanced wear sensors. They are used for the continuous monitoring of ferromagnetic wear particles in hydraulic and lubrication systems. The sensors work according to an innovative principle in which ferromagnetic particles are attracted and collected by an integrated permanent magnet.

A central component of the OPCom FerroS wear sensor is a planar coil that is integrated into an oscillating circuit. When ferromagnetic particles hit the coil, the parameters of the oscillating circuit change in proportion to the amount of particles collected.

These changes are converted into normalized values that indicate the degree of saturation of the coil. As soon as the maximum degree of saturation is reached, the magnetic field can be automatically compensated, releasing the collected particles. This makes the wear sensor maintenance-free and enables continuous monitoring of a hydraulic system without the need for manual, time-consuming inspections.

Continuous monitoring by the sensor also makes it possible to record and predict wear processes in real time. This enables predictive maintenance. Potential machine failures can be detected at an early stage and avoided before defects occur.

For example, the OPCom FerroS can be used in wind turbine gearboxes, to monitor the wear of drive components. This can extend the service life of the machines. Expensive, unproductive machine downtimes become largely superfluous.

How does the monitoring of wear particles with OPCom FerroS work?

During the operation of hydraulic systems and machines, the components used gradually wear out. This causes metallic particles to enter the oil, the number of which increases as the element wears. The OPCom FerroS sensor is the first sensor on the market that enables effective monitoring of this type of contamination. It is based on the principle of capacitive measurement of ferromagnetic particles in the oil.

The wear sensor measures the amount of ferromagnetic particles in the oil. It converts this information into a proportional output signal of 4 to 20mA. It indicates the degree of damage to the monitored devices. Continuous monitoring makes it possible to monitor the condition of the machines in real time. In addition, preventive maintenance measures can be planned in good time to avoid expensive breakdowns and repairs.

The OPCom FerroS wear sensor is operated with a voltage of 22 to 33 VDC. It can monitor both fine and larger particles. This enables a comprehensive analysis of the wear situation in the machines. By combining the signals, a complete picture of the machine condition can be created. This enables precise monitoring and timely maintenance.

This technology offers numerous advantages, such as a longer service life for machine components, reduced operating costs and improved machine reliability. The ability to continuously monitor wear particles is particularly important in demanding industrial applications. It significantly improves the efficiency and safety of production processes.

The use of OPCom FerroS sensors in combination with the LubMon Connect cloud solution also enables a modern and comprehensive monitoring solution. It is based on real-time data and supports predictive maintenance. For local usage of this sensor, you can combine it with LubMonVisu.

What are the advantages of OPCom FerroS sensors compared to laser-based monitoring systems?

OPCom FerroS sensors offer a reliable solution for monitoring wear particles in oil that differs significantly from laser-based systems.

A major advantage of the sensor is that it does not require small flow channels. These are often necessary when using laser-based systems. As a result, the sensor can effectively measure both large particles and fine particles below 4 micrometers. This ability to detect a wide range of particles makes it particularly valuable for applications where comprehensive monitoring is required.

Another key advantage of OPCom FerroS sensors is their independence from water and air bubbles in the oil. This is particularly important in gearboxes where such interference factors can occur frequently. This independence enables the sensor to carry out precise measurements. This is because the results are not affected by the presence of water or air bubbles.

The sensor's integrated operating hours counter saves the values even after a power failure. As a result, it continues to work from the last saved value after the interruption. This function enables continuous monitoring and ensures that no operating time is lost.

By detecting wear and damage at an early stage, the OPCom FerroS sensor enables predictive planning of maintenance measures. This helps to minimize downtime and maximize machine efficiency. The sensor also offers various communication options, including an analog 4-20mA output signal and digital interfaces such as RS232, CANOpen and SAE J1939.

Advantages of the OPCom FerroS sensor

These are the advantages of the sensor at a glance:

  • Captures both large and fine particles under 4 micrometers
  • No interference from small flow channels as with laser-based systems
  • Accurate measurements even in the presence of water or air bubbles in the oil
  • Ideal for use in gearboxes and other applications with frequent interfering factors
  • Reliable performance in demanding environments
  • Integrated operating hours counter that stores values even after power failures
  • Enables predictive maintenance planning
  • Minimizes downtime and reduces operating costs
  • No manual inspections required
  • Support for machine predictive maintenance
  • Can be connected to the ARGO-HYTOS cloud solution

Get advice on the OPCom FerroS sensor from ARGO-HYTOS

The OPCom FerroS sensor from ARGO-HYTOS offers your company a comprehensive solution for monitoring wear particles in hydraulic systems. The precise measurement of both large and fine ferromagnetic particles in demanding environments makes the solution an economical alternative to laser-based monitoring systems.

The sensor has proven itself in gearboxes and wind turbines in particular thanks to its reliable performance and integrated operating hours counter. This saves the data even after a power failure and then continues counting. The early detection of wear enables efficient maintenance planning and minimizes downtimes. This ultimately reduces operating costs and extends the service life of the machines.

Would you like to find out more about how the OPCom FerroS sensor can improve the efficiency and reliability of your machines? Then get in touch with us and let our experts advise you in a personal consultation!

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