IR4.0 solutions for Hydraulic Maintenance By Nor Azilan Jaafar - - PowerPoint PPT Presentation

IR4.0 solutions for Hydraulic Maintenance

By Nor Azilan Jaafar German Malaysian Institute

Machinery & Equipment Productivity Nexus (MEPN) MCO Webinar - Awareness Program for M&E Industry 16 April 2020 3:00 – 4:00 PM

Introduction

• Welcome to Maintenance Hydraulic with

IR4.0 Solution

• I will introduce on Hydraulic system

conventional troubleshooting and maintenance and will share information how to use sensors as IoT data generation for better understand and enhance the

• peration of your hydraulic equipment.

01 02

Corrective Maintenance

Hydraulic Oil Level Hydraulic Temperature & Odor Hydraulic Oil Type ISO VG

2

03

Oil Level

• One of the main issue

in a hydraulic system is

• leakages. One drop of
• il that drips once per

second will lose 1500 litres a year.

• This will effected the pump

efficiency, malfunction and pressure drop, bubbles and air trap.

Level & Temperature Sensor with IoT

Float Sensor Ultrasonic Sensor RTD/PT100 Sensor

04 05

Corrective Maintenance

Hydraulic Oil Filter Hydraulic Pumps Hydraulic Actuator and Seals

2

06

Filter with sensor indicator

Sensor on hydraulic pump with IoT

Linear position sensor

+

Linear Position Sensor Pressure Sensor

07 08

Corrective Maintenance

Electrical Control Proportional Valve Sensor interlock

2

09

Digital data from Electrical Panel to IoT

Oil Temperature

• On any given hydraulic system,

there should be some line that are hot (above 130 °C ), warm (100 – 130 °C)

• This will effect the oil

contamination (sludge & varnish), high viscosity, damaging the seals, fittings and actuators steels. The heat exchanger or cooling unit very important to control the oil temperature.

Oil Chiller

The oil chiller is a unit which performs cooling of the hydraulic oil, lubricating oil and cooling oil of machine tools. In various parts of the machine tool spindles the bearings and gears get overheated and thermal deformation occurs due to the high speed rotational impact

Hydraulic Type ISO Standard (Grade/Code)

ISO 3448 Viscosity class Kinematic viscosity at 40°C [mm2/s = cSt] Mid-point Minimum Maximum ISO VG 2 2.2 1.98 2.42 ISO VG 3 3.2 2.88 3.52 ISO VG 5 4.6 4.14 5.06 ISO VG 7 6.8 6.12 7.48 ISO VG 10 10 9.0 11.0 ISO VG 15 15 13.5 16.5 ISO VG 22 22 19.8 24.2 ISO VG 32 32 28.8 35.2 ISO VG 46 46 41.4 50.6 ISO VG 68 68 61.2 74.8 ISO VG 100 100* 90 110 ISO VG 150 150 135 165 ISO VG 220 220 198 242 ISO VG 320 320 288 352 ISO VG 460 460 414 506 ISO VG 680 680 612 748 ISO VG 1000 1000 900 1100 ISO VG 1500 1500 1350 1650

Oil Filter

You should come across the following information to select the correct filter. 1. Beta rating

• 2. Type of the filter media
• 3. The filter’s model number and size
• 4. Filtration efficiency

Get advice from OEM / Manuals for different type of filter for Suction Filter, Pressure filter, Return Filter, Pilot Liner Pressure Filter & Offline Filter. Stainless Steel filter 25~80 um Fiber glass filter 1~20 um Cellulose filter 5-40 um Mesh Micro Glass filter 5~40 um Paper filter 1~10 um

Hydraulic Pump

Bent Axis type Gear Type Axial type Rotary vane type Screw type Radial type Throcoid type

Pump Diagnosis Through Case Drain

Axial Pump Vane Pump

2

Actuator Seals

Piston Seal Bearing Rod Seal Rod Wiper Seal

Type of seals in actuator Silicone Viton Nitrile EPDM (Synthehtic Rubber) Get recommendation from machine manuals type of seals

Pressure Setting (Pressure Relief Valve)

• One of the biggest

problem in systems today is that the pressures are out of adjustment.

• This problem will cause

excessive force heat, leakage and wasted electrical energy.

Preventive Maintenance

OIL LEVEL

01

2

Most companies make very few Preventive Maintenance checks such as;

FILTER CONDITION

02

LEAKS FITTINGS

03

PUMPS AND MOTOR COUPLING

04

BREATHER,

OCCUMULATOR , PRESSURE RELIEF VALVE

05

SEAL AND GASKETS

06

Daily Maintenance

3 1 7 5 2 4 6 8

Check Oil Level Check oil contamination

• dour

Tighten Screws/pipe coupling Monitor running noise from pump Check Oil Temperature Check any Leaks Verify Pressure gauge readings Keep surface pipe, pump, valve and tank clean

2

+ 6 Weeks Maintenance

Check

• r

replace Filters Clean Strainer Replace fittings or hoses if continue leak Check and replace any leaking seal Check Hydraulic actuators

• r

cylinders

01 01 03 04 05

2

2

+ 6 Months Maintenance

Oil Sampling Test

01

Check Occumulators

02

Check AC Motor + Coupling

03

Check Breather

05

Check Pressure Relief Valve

04

01 02

Send an oil sampling to check for viscosity /quality /contamination & wear. Check the gas pre-charge level

• regularly. Check

the correct pre- charge

04

Checking the maximum system pressure

05

Check any clogged filtered, Check AC motor copling and AC motor condition

03

Dismantling pump & cleaning

2

Annual Maintenance 01 02 03 04 05

Changing new Hydraulic Oil Dismantling proportional valve & cleaning Cleaning reservoir tank & inlet strainer cleaning. Cleaning diffuser and buffle plate reservoir

CMMS

Predictive Maintenance

PRESSURE FLOW SYSTEM VIBRATION OIL QUALITY TEST TEMP

• Pressure

sensor

• detect daily

pressure

• recorded

and present historical data.

• High flow

meter sensor

• detect daily
• il flow.
• recorded &

present historical data

• PT100 /

Thermocou ple sensor

• detect daily

temp.

• Recorded

and present historical data

• Vibration

sensor

• detect daily

vibration effect

• Recorded

and present historical data

• Oil sampling from

downstream point.

• To find any

correlation result. Contents of ; i. Ferrous ii. Particles iii. Nitrat iv. Oxidation v. Potasium, Sodium

Predictive Maintenance with CMMS and IoT

Output from Sensors present historical data (Example)

EXAMPLE EXAMPLE EXAMPLE EXAMPLE

Continuous Oil Condition Monitoring

Conclusion

1