美国开放式系统公司

WearSens®WS3000

在线、连续监测以预防齿轮箱和轴承故障的新方法！

WearSens® 是用于在线油况监测的一种独特的新系统。机油变化的早期指标可以帮助用户优化最佳负载量或及时进行预防性维护，从而节省了大量金钱、停机时间和工时。

机油油质的变化是轴承滚道中颗粒剪切和点蚀的先兆之一。在损坏发生之前，及早发现可以对可能造成的损害进行预警。

WearSens®在安装的第1天就开始监测，能够在传统技术检测上限之前就能监测到机油状态变化。我们的测试表明，WearSens®可以检测出机油的变质，而标准实验室分析仍然认为机油质量良好，至于振动监测和颗粒计数，则是在设备磨损已经发生后才能检测到。

我们对电导率、介电常数和温度的测量精度都非常高。电导率和介电常数均与温度有关，但是对任何单一的污染物的温度补偿是很复杂的。WearSens®具有类似于神经网络的自适应温度补偿算法，能够有效解决此问题。

电导率以皮西门子/米为单位进行测量，灵敏的电导率测量值可以检测到破裂的油分子形成的化合物，可能存在的微粒以及任何添加剂的消耗，而且温度补偿是随时进行的。

相对介电常数是介电常数的量度。当添加剂消耗时，介电常数会降低，但一旦所有添加剂消耗完，介电常数又会上升，结合电导率参数值，我们就可以清楚地了解到机油状态的变化。基于Web的，去中心化的监控系统非常适合对偏远或无法到达的设备进行监测。 测量值通过LAN，WLAN或串行接口传输。

WearSens®是在德国研发和制造的，代表了一种在各种应用中对在用油进行油况监测的全新方法，实现在线、连续、准确地检测机油的变化，这在行业内尚属首次。因此，可以为用户优化负载，减轻磨损，节约费用。

早期探测方法仅对滚道内已发生的、不可逆的损坏进行检测，而这种创新的方法能做得更

多。传感器的组件测量油的复数阻抗。例如，金属磨损，破碎的油分子，酸或油皂的影响都

会增加电导率。高质量的添加剂油将以分钟为单位的来消除油中的离子和酸化作用，但

WearSens®系统会以秒为单位的来测量电导率的变化。因此，WearSens®将在添加剂被消耗

完之前就检测到磨损。

借助WearSens®系统，用户可以监测到由摩擦引起的不同“摩擦层类型”（例如附加条件边界

层，氧化铁层）的降解。

WearSens系统与传统光学颗粒测量/计数系统的区别和优势

The crucial difference between the two sensors is that the WearSens® system is used to prevent damage and

limit wear, however, the particle counter displays damage done.

两类系统最重要的区别是:WearSens系统的应用是 防止损害，并且减轻磨损，而颗粒计数系统是在损害已

经造成后的检测

在损害已

经造成后的检测。

The optical particle counter detects particles from a size of 4 microns. From the number of particles, it provides

conclusions about the state of wear or existing damage.

光学颗粒计数系统是探测4微米以上的颗粒，从探测到的颗粒数量来判断 磨损程度或者设备损害程度。

The task of the WearSens® sensor system is to minimize the wear and avoid potential damage.

WearSens系统的目的是 将磨损减轻到最低，并且避免对设备可能造成的损害

Ideally suited for the early detection of damage, it detects changes in the oil-machine system by measuring

from the outset before any damage occurs (see Figure 1). The smallest amount of wear is detected reliably. The

sensor system continuously determines the quality of oil from the dependent parameters of the electrical

conductivity and the dielectric constant. With this approach of measuring the change in the oil-machine system, a

quasi-continuous assessment of the wear, as well as the contamination and deterioration of the lubricating oil,

has been realized. In addition, preventive maintenance measures are indicated. The sensor system increases the

operational reliability, increases service life and reduces downtime periods. Oil change intervals are adjusted to

actual needs and economic and ecological efficiency improvements are achieved.

WearSens系统非常适合对设备进行 早期磨损监测，在设备损坏还没有发生前就开始监测

机油-机械系统的油状态变化情况（参见图一）即使是最轻微的磨损都能可靠地监测到，该系

统能够连续地通过对机油电导率、介电常数的监测来判断机油质量，因此可以对机油-机械系

统的磨损、润滑油污染和劣化等进行连续、实时地监测，与此同时，预防性维护措施可以确

保机械设备能够更可靠地运转，延长机械服务年限，减少停机时间，另外，机油更换周期也

可以根据实际需求来调整，从而提高经济效益。

WearSens® is an online, continuous system for oil condition monitoring. This permits the reliable detection

of incipient damage and the early identification of critical lubrication conditions of bearings and other

transmission elements in the gearbox. Wear of the bearing at touching contact surfaces, metal debris,

foreign particles, suspended solids and chemically broken oil molecules, which forms acids or soaps all lead to

an increase in the electrical conductivity. This increase directly correlates to gear wear and the degree of

contamination of the oil due to the initial low conductivity of the oil and relatively high conductivity of the

contamination products.

WearSens ® 是一种在线，连续的机油状况监测系统。这样可以可靠地检测出初期损坏，并及

早识别齿轮箱中轴承和其他传动元件的关键润滑状况。轴承在接触表面上的磨损，金属碎

屑，异物，悬浮的固体和化学破碎的油分子（形成酸或肥皂）都会导致电导率的增加。由于

油的初始低电导率和污染产物的相对高电导率，因此电导率的上升与齿轮磨损和油的污染程

度直接相关。

In oils with additives, the consumption of these can be detected via an additional high-

precision measurement of permittivity. Continuous evaluation of the chemical aging of the lubricant during

operation opens up a new method for preventing premature bearing failures, occurring under vibration-

induced mixed friction stress conditions, e.g. in wind energy turbines and other industrial

gears, by timely implementation of appropriate corrective measures, such as additive addition or oil

change.

在含添加剂的油中，可以通过高精度介电常数测量来检测其消耗情况。在机械运行过程中连

续评估润滑剂的老化开辟了一种新的方法以防止在振动引起的混合摩擦应力条件下导致轴承

过早失效。在风能涡轮机和其他工业齿轮中，应及时采取适当的纠正措施，例如添加添加剂

或换油。

This innovative approach goes far beyond the simple early detection of incurred, irreversible damage to

the raceway. The components of the sensor measure the complex impedance of the oils. For example,

effect of metal wear, broken oil molecules, acids or oleic soaps all increase the electrical conductivity.

High quality additive oils will nullify the resulting ions and the acidification of the oil with time constants in

the range of minutes but the WearSens ® system measures changes in conductivity with time constants in

This creates new opportunities in the development phase of the gears and bearings. By understanding

wear mechanisms, optimization of the system can be performed and thus increased operating time.

这就在齿轮和轴承的开发阶段创造了新的机会。通过了解磨损机理，可以对系统进行优化，

从而延长了设备服务寿命。