Eaton Particle Flow Sensor Detects Oil Contaminants
Eaton’s Filtration Division has developed a compact particle flow sensor to provide continuous contamination monitoring of hydraulic and lubrication oils. The PFS 02 sensor is able to provide immediate and accurate diagnoses of contamination levels within a system.
Contaminants, no matter how small, can cause major performance issues if they get into hydraulics and other systems. But with a sensor like the PFS 02 installed in a system, the chances of these performance issues occurring and causing unplanned downtime can be reduced.
Sending alerts to machine operators when particle concentration rises allows them to address the issue as soon as possible, minimizing downtime as well as larger maintenance problems.
“We see an increasing use and demand for such sensors,” said Simone Ortner, Hydraulic Filtration Engineering and Product Manager at Eaton Filtration. “In our opinion, there are several factors contributing to this. The sensors help prevent failures and extend the lifespan of machines. Additionally, by detecting wear early, expensive repairs and downtime can be reduced, thereby saving costs.”
How Eaton Achieved a Compact Particle Flow Sensor Design
The PFS 02 particle flow sensor is an in-line device which can detect solid particles starting from a size of 4µm. To do so, Ortner said it operates based on the light blockage principle.
Previously, Eaton’s particle measuring devices consisted of two separate components — the sensor and the evaluation unit. But the PFS 02 brings them together into a single unit. To achieve this, Ortner said the company used newer and more compact electronic components.
In addition, she said an additional flow sensor is no longer used. “We now determine the flow rate in a different way,” she said. “This has allowed us to save significant space and integrate everything into a single compact housing. The advantage is that the user only needs to install one component.
“Additionally, the improved technology in a single housing unit provides enhanced accuracy,” she noted.
The company also set out to design a particle flow sensor capable of operating at pressures up to 420 bar (6,000 psi). Ortner said this required extensive testing and optimization of the latest technologies.
By having the ability to work at such high pressures, the particle flow sensor can be used in a wide range of mobile and industrial machinery applications such as construction equipment and test benches. “It can also be used in gearboxes for the early detection of wear,” she said.
Digital Communication Enables Proactive Maintenance
According to Ortner, extensive communication capabilities were incorporated into the PFS 02 sensor based on customer feedback. Doing so allows measuring results to be provided via a serial or CANbus interface, she said.
An analog 4-20 mA interface is included on the sensor as well, enabling customers to use the output interface that best suits their needs. Ortner said that a benefit offered by the PFS 02 sensor is that it “outputs only one 4-20 mA signal, compared to the three signals in our previous models, reducing the need for additional analog inputs.”
Measurement results are shown on the sensor device’s graphic display to provide easy monitoring for users. Results can be displayed according to ISO 4406:99, SAE AS 4059, NAS 1638 and GOST 17216 standards.
With these communication capabilities, machine users can be better prepared to address issues as they arise to help minimize unplanned downtime and maintenance — both of which can be costly and time consuming. And by addressing contamination issues early, wear and tear can be reduced, leading to longer system and machine life.
Through its creation of the PFS 02 particle flow sensor, Eaton is helping address industry challenges associated with reliability and downtime by providing customers with a way to detect the presence of contaminants in hydraulic fluids and lubricant oils before they cause performance issues or system failures.
