Classifications

• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
  • G01N33/26—Oils; Viscous liquids; Paints; Inks
  • G01N33/28—Oils, i.e. hydrocarbon liquids
  • G01N33/2835—Specific substances contained in the oils or fuels
  • G01N33/2847—Water in oils
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
  • G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
  • G01N27/28—Electrolytic cell components
  • G01N27/30—Electrodes, e.g. test electrodes; Half-cells
  • G01N27/307—Disposable laminated or multilayered electrodes
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
  • G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
  • G01N27/416—Systems
  • G01N27/4163—Systems checking the operation of, or calibrating, the measuring apparatus
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
  • G01N33/26—Oils; Viscous liquids; Paints; Inks
  • G01N33/28—Oils, i.e. hydrocarbon liquids
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
  • G01N33/26—Oils; Viscous liquids; Paints; Inks
  • G01N33/28—Oils, i.e. hydrocarbon liquids
  • G01N33/2835—Specific substances contained in the oils or fuels
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
  • G01N33/26—Oils; Viscous liquids; Paints; Inks
  • G01N33/28—Oils, i.e. hydrocarbon liquids
  • G01N33/2888—Lubricating oil characteristics, e.g. deterioration

Definitions

• the present invention relates generally to fluids and more particularly to an apparatus and method for evaluating the condition of an organic fluid required by operating equipment to perform properly.
• the condition of a fluid is evaluated based on the degree of basestock oxidative degradation, degree of additive(s) depletion, levels of liquid and solid contaminants, and other parameters that affect the fluid's ability to perform its required functions in operating equipment.
• Fluid such as oil or fuel
• Fluid is often used to lubricate and cool components of operating equipment as well as remove generated particles from moving surfaces.
• the fluid circulating in normally operating equipment experiences thermal and oxidative stresses along with a wide range of contamination that slowly decrease the condition of the fluid, i.e., shorten the fluid's useful life.
• fluid change-outs are performed on a regular schedule based on operating time, mileage, or other operational parameters. Since not all equipment of the same type decrease the condition of operating fluid at the same rate, the scheduled change- outs are conservative to ensure no circulating fluid, regardless of the particular equipment operating conditions, is used past the end of its useful life.
• worn or damaged components as well as external forces or contaminants cause equipment to operate abnormally resulting in accelerated oxidation and/or contamination of the circulating fluid.
• a method and an apparatus that monitor the condition of the fluid by measuring a number of parameters of the fluid.
• the present invention uses multiple sensors to measure the vapor and liquid properties of the fluid at different temperatures and after different fluid treatments. From these measurements, the condition of the fluid can be determined.
• a sensor device for monitoring the condition of a fluid comprising a member, a plurality of liquid sensors measuring liquid parameters of a fluid coupled to the member, and a plurality of vapor sensors for measuring vapor parameters of a fluid coupled to the member, wherein the plurality of liquid sensors and plurality of vapor sensors are positioned a distance from one another so that the plurality of vapor sensors do not contact the liquid.
• a sensor device for monitoring the condition of a fluid comprising a member, a plurality of liquid sensors measuring liquid parameters of a fluid coupled to the member, a plurality of vapor sensors for measuring vapor parameters of a fluid coupled to the member, wherein the plurality of liquid sensors and plurality of vapor sensors are positioned a distance from one another so that the plurality of vapor sensors do not contact the liquid, and a display system coupled to the end of the member opposite to the liquid sensors.
• a method for monitoring the condition of a fluid including the steps of providing a sensor device having a plurality of liquid sensors and a plurality of vapor sensors on a member; placing the member in a fluid such that the plurality of liquid sensors are immersed in the fluid and the plurality of vapor sensors do not come in contact with the fluid; measuring at least one parameter of the fluid; analyzing measurements of the fluid at different temperatures; and determining the condition of the fluid.
• Fig. 1 is a schematic illustration of a sensor device having a plurality of vapor sensors and a plurality of liquid sensors according to one embodiment of the present invention.
• Fig. 2 is a schematic illustration of a sensor device having a plurality of vapor sensors and a plurality of liquid sensors according to another embodiment of the present invention.
• Fig. 3 is a flow chart of the sensor device's electronics according to one embodiment of the present invention.
• Fig. 4 is a graph showing the liquid sensor output versus temperature relationship according to the present invention.
• Fig. 5 is a graph showing the vapor sensor output versus temperature relationship according to the present invention.
• Fig. 6 is a schematic illustration of the plurality of liquid sensors in another embodiment according to the present invention.
• Fig. 7 is a schematic illustration of using one embodiment of the present invention to measure viscosity.
• the present invention is a sensor device 10 that includes a plurality of liquid sensors 20 and a plurality of vapor sensors 30 that when used in conjunction with one another, can provide a thorough evaluation of the fluid to monitor the condition of the fluid.
• the present invention allows for a compact, efficient, and economically feasible manner to monitor the condition of a fluid directly inside the operating equipment, via an on-line/on-board sensor device.
• the sensor device is adapted to measure fluid level, viscosity, temperature, electrical conductivity, electrochemical activity, water contamination, wear metals, soot buildup, coolant contamination, fluid level, and combinations thereof. Furthermore, the sensor device 10 allows for the lengthening of fluid sampling intervals of the monitored piece of equipment. In addition, the sensor device 10 allows for lengthening the fluid change out intervals of different equipment with the insurance that the useful life of the fluid will not be exceeded due to overuse. Further, the sensor device 10 increases the capabilities of an equipment operator to detect abnormally operating equipment at an earlier stage.
• the sensors 20 and 30 are coupled to a member 12 having a first member end 12a and a second member end 12b.
• member 12 is made of a conductive material to match the composition of surrounding components such as cast iron, stainless steel, aluminum or any other suitable metal.
• the member 12 may also be made of a nonconductive material such as tetrafluoroethylene, high density polyethylene, polyimide polymer used for circuit boards, any other plastic or composite material dimensionally and chemically stable at the operating temperature of the monitored equipment, and combinations thereof.
• Member 12 is sized to be accommodated in the conventional dipstick port used in engines or other operating equipment with a fluid reservoir for checking the level of the operating fluid, such as, for example, oil.
• Member 12 can be a conventional dipstick.
• the number and type of sensors utilized by the sensor device 10 can be preselected based on the degradation/contamination mechanisms of the equipment to be monitored.
• the sensors 20 and 30 are arranged on the member 12 in a manner such that the plurality of liquid sensors 20 may be fully immersed in a fluid 11 while the plurality of vapor sensors 30 do not come into contact with the fluid. Therefore, the vapor sensors 30 only measure parameters of the vapor portion of the fluid.
• the liquid sensors 20 measure the temperature and electrical properties of the fluid. In one embodiment, the electrical properties are measured using single electrode conductivity and triangular waveform voltammetry methods that are disclosed by U.S. Patent Nos. 5,933,016 and 5,071,527, respectively and the disclosures of which are herein incorporated by reference. Other electrical properties measured may also include capacitance, dielectric constant, and the like.
• the liquid sensors 20 can be conductive line surfaces 27 on a nonconductive substrate 29, forming a sensor array 28 and/or can be a series of wire rods 22, 23, 24, and 26.
• insulation 14 is placed in between the liquid sensors 20 and over portions of the wire rods that are exposed to the fluid.
• the wire rods 22, 23, 24, and 26 are placed between about 0.1 mm to about 100 mm apart from one another, and more specifically about 1 mm apart from one another.
• the sensor array 28 comprises sensors that are spaced between about 0.001 mm to about 1 mm apart, and more specifically about 0.075 mm apart.
• the liquid sensors 20 can be comprised of any suitable corrosive resistant, conductive material.
• Suitable materials include, but are not limited to, glassy carbon, platinum, gold, copper, copper alloys, nickel alloys, stainless steels, and combinations thereof.
• the liquid sensors are made of nickel or 316 stainless steel.
• the insulation 14 and nonconductive substrate 29 can comprise tetrafluoroethylene, high density polyethylene, polyimide polymer used for circuit boards, alumina, any other nonconductive material dimensionally and chemically stable in the fluid environment of the operating equipment, and combinations thereof.
• the plurality of vapor sensors 30 contact only the fluid vapors, and are sensitive to fluid oxidation and/or condensing water droplets.
• Fluid oxidation or water droplets 31 typically form after stopping the equipment, such as an engine, as compounds condense from the hot fluid onto a cooler portion of the sensor device 10, such as first member end 12a.
• Fluid oxidation or condensing water droplets 31 can form while the engine is operating; in this case the vapor sensors 30 and liquid sensors 20 operate simultaneously. Therefore, when the engine shuts down or at any point when the fluid becomes sufficiently hot that oxidation products and/or water evaporates then condenses onto the cooler portion of the sensor device 10, condensing droplets 31 form and adhere to the vapor sensors 30. The sensor then measures the vapor parameters.
• the vapor sensors 30 can be conductive line surfaces 27 provided on a nonconductive substrate 29, forming an array sensor, and/or can be a series of wires (not shown).
• the conductive line surfaces 27 and/or wires are placed between about 0.1 mm to about 50 mm apart from one another, and more specifically about 1 mm apart from one another.
• the sensor array comprises sensors that are spaced between about 0.001 mm to about 1 mm apart, and more specifically about 0.075 mm apart.
• the vapor sensors 30 can be comprised of any suitable corrosive resistant, conductive material.
• Suitable materials include, but are not limited to, glassy carbon, platinum, gold, copper, copper alloys, nickel alloys, copper alloys, stainless steel, and combinations thereof.
• the vapor sensors 30 are made of nickel or 316 stainless steel.
• insulation 14 is placed in between the vapor sensors 30 and over areas of the sensor not exposed to the fluid vapors.
• the insulation 14 and the nonconductive substrate 29 can be tetrafluoroethylene, high density polyethylene, polyimide polymer used for circuit boards, alumina, any other nonconductive material dimensionally and chemically stable in the fluid environment of the operating equipment, and combinations thereof.
• an electronic system 40 is coupled to the first member end 12a of sensor device 10.
• the electronic system 40 is electrically connected to the sensors 20 and 30 and shows the overall condition and level of the fluid or can be modified to indicate a particular degradation/contamination mechanism of interest to the user.
• the electronic system 40 includes the electronics for the sensors 41, a readout display 42 and a reset button 44.
• the electronics 41 include a power source 60 which provides power to the central processing unit 62 (CPU), memory 64, data port 66, and the display system 72.
• the display system 72 includes the display driver 68 and the display 42.
• the electronics 41 calculate the condition or level of the fluid by using an algorithm based on the degradation/contamination mechanism being monitored and the measurements taken from the vapor 30 and liquid sensor 20 outputs.
• the CPU 62 uses the algorithm stored in memory 64, and information supplied to it from the data port 66 via sensors 20 and/or 30 to calculate the measurements for conditions that are being monitored. It is to be appreciated that data port 66 includes the necessary electronics to convert analog data from sensors 20 and/or 30 into filtered, digital information in a format suitable for handling by the CPU 62.
• the CPU 62 relays the calculated measurement(s) to the display driver 68.
• the display driver 68 then formats the measurement(s) to the display 42 such that the user may view it.
• the computations performed by the CPU 62 include the determination of accelerated oxidative degradation due to end of useful life or abnormal operating conditions, coolant/water contamination, soot build-up, viscosity change, accelerated wear, thermal breakdown of additives due to fires or hot spots and fluid level.
• power for the electronics 41 may be supplied by an external source, or an intended battery.
• computer algorithms and other initialization data may be loaded into the memory 64 from an external computer 70 also via data port 66, if so desired.
• sensor data and computed measurements can be provided to the external computer 70 directly, from the CPU 62, sensors 20 and/or 30, and/or memory 64 via data port 66, if so desired.
• computer 70 may be communicably coupled to the electronics 41 via a cable connection, network connection, or via a wireless technology such as radio frequency wireless.
• the reset button 44 is located anywhere on the display system and may be pressed when the fluid is changed so that the device can reset the time being recorded and recognize sudden change in readings due to the fluid change.
• the sensor device 10 By attaching the electronic system 40 to the member 12, the sensor device 10 provides the user a quick easy look at condition of the fluid. While the electronic system 40 is shown coupled to the first member end 12a of the member 12, it is to be appreciated that the display system 40 may be coupled to the member 12 in any area convenient for the user. Referring again to Fig. 2, when wire rods 22, 23, and 24 are used as the liquid sensors 20, the level of the fluid can be approximated by the following methodology. If the fluid contacts sensor 22 and sensor 23 the fluid completes the circuit between the two adjacent wire rods and the FULL light on the display 42 illuminates.
• the display 42 is located on the display system 40. However, if the fluid level is too low to contact the sensors 22 and 23, but still contacts sensors 23 and 24 then l / ⁇ FULL illuminates in the display 42. When the fluid no longer contacts sensor 24 then the electrical circuit is broken and then ADD illuminates in the display 42.
• the light system illustrated in Fig. 2 could be replaced by a Liquid Crystal Display (LCD) with numerical/text readouts to conserve battery-life and to make the sensor output easier to modify. With a LCD a continuous, more accurate fluid level could be shown on display 42. When the fluid completely submerges the entire exposed portions of wire rods 26, the outputs of wire rods 26 and array 28 can be set to be equal and display 42 can be set to read 100% full.
• LCD Liquid Crystal Display
• the ratio of the output of wire rod 26 to the output of array 28 could be shown by display 42 as a percentage, e.g., 70%. This reading provides an accurate level reading and rate of level decrease, allowing for timely repairs when needed. It is to be appreciated that sensors other than wire rods can be used to indicate the fluid level; however, such alternative sensors should be completely submerged to accurately indicate the fluid level as full.
• a sensor array 28 having at least one magnetized line or a magnet is placed behind the liquid sensors 20 when using a sensor array 28.
• the magnet or magnetized line helps the sensor array 28 to indicate the wear rate of the monitored equipment, such as an engine, on the fluid.
• the sensor's output increases.
• the circuit is completed and the sensor is electrically shorted.
• the difference between the output of the sensor array 28 having a magnetic field attached (off-scale) and the output of a sensor array 28 or other liquid sensors 20 without a magnetic field (on-scale) is then attributed to the accelerated production of ferrous wear particles in the fluid by severe wear processes indicating maintenance action is necessary to repair the wearing part.
• the sensor array 28 can then be removed to allow inspection of the collected debris to aid the user to identify the wearing part and the severity of the wear mechanism, i.e., the composition and size of the particles.
• the magnet or magnetized lines can be, Alnico which is a special aluminum-nickel-cobalt alloy, a ceramic such as barium or strontium ferrite, or a rare earth magnet such as Neodymium iron boron or samarium cobalt, or any other permanent magnet that retains its magnetism to temperatures above 700° F.
• Applied voltage waveforms such as square, sine, and triangular waveforms, may be applied to the fluid to increase the sensitivity of the sensor device 10.
• sine waveforms typically occur between about ⁇ 0.5V and +15V, specifically at ⁇ 3 V.
• cycle rates are typically less than 1000 Hz, specifically at 1Hz for conductivity and 500 Hz
• waveform typically occurs between ⁇ 1 and ⁇ 20 N, specifically at ⁇ 15 N and at cycle rates
• the sensor device 10 uses a triangular waveform in conjunction with the sensor device 10 causes electrolysis of the water with a resulting increase in current flow. This increase in current flow increases the sensor device's 10 sensitivity to water.
• the applied voltage waveforms may be supplied to the fluid by any suitable waveform generator. Taking the sensor measurements in the liquid at different temperatures further increases the condition monitoring capabilities of the sensor device 10. For example, after the fresh oil is added to an engine, the sensor output should increase linearly or in a consistent manner with the fresh oil's temperature, indicating that the fluid is not oxidized. As the oil becomes oxidized, the liquid sensors 20 increase exponentially with temperature.
• the deviation from the normal linear increase from the fresh oil plot versus the temperature increase of the oxidized oil is proportional to the degree of oxidation.
• the increase in sensor output can be established for set temperatures for the fresh oil. The established output is compared to previous fresh oil readings to ensure the proper oil was used for the change out. An algorithm can be created from the data to calculate the measurement of the output.
• Fig. 4 is a graph showing a sensor output versus temperature relationship for an aircraft engine accelerated oxidation test and is indicative of the degree of oxidation.
• the graph indicates that as the temperature increases, the output of the liquid sensor also increases.
• Engine Run 8 indicates the beginning of oxidation by showing outputs of liquid sensors increasing slightly with the increasing of the oil temperature as illustrated along the y-axis. The temperature of the oil increased from 260° F (4400 RPM) up to 420° F (9900 RPM) which resulted in an increase in the outputs of liquid sensors #1 and #2 by less than 50%. However, by Engine Run 10 as temperature increases, the outputs of the liquid sensors increased by greater than 400%.
• an increase in the liquid sensor output of 50% at a preset temperature or temperature increase is considered abnormal and indicative of engine problems, i.e., cracked seal.
• the rate of increase is also important. If the liquid sensor output goes from normal to off-scale in a matter of minutes, the sudden increase is indicative of a hot spot or an engine fire.
• an increase in the liquid sensor output of 200% at a preset temperature would be tolerable and be indicative of the need for an oil change rather than an engine problem.
• the vapor sensor readings are only affected by volatile oxidation compounds and where applicable, water condensation and smoke.
• An algorithm can be created from the data to calculate the measurement of the output.
• the vapor sensor readings provide an unchanged baseline until oil begins to oxidize.
• the oil is starting to oxidize as indicated by the increased output by the sensor.
• the vapor sensor readings only increase when accelerated oil oxidation is occurring.
• the output increases as the sensor environment cools, and/or the volatile compounds condense.
• Napor sensors only have an output when accelerated oxidation or abnormal operating conditions are occurring and are independent of fluid composition or additive package.
• the sensor device 10 another embodiment of the present invention can measure viscosity in a stagnant system.
• the member 12 is placed in an area where the fluid flow, such as for example, in valves or chambers.
• the rate at which the fluid flows from one chamber to another, for example, through a supply line at shut down, can be used to estimate the viscosity of the in-service fluid.
• an oil collection point such as the oil pan
• upper sensor 3 positioned in the engine becomes less covered by the fluid. This results in a decreased sensor output by upper sensor 3 as compared to the sensor output of sensor 21 , which remains submerged in the oil.
• the rate at which the output of upper sensor 3 decreases with respect to sensor 21 is directly proportional to the viscosity of the fluid, i.e., the more viscous the oil, the slower the oil drains from the surface of upper senor 3 and the slower the output of upper sensor 3 decreases with respect to the output of sensor 21.
• the viscosity of the fluid is determined.
• a method for measuring the viscosity in a flowing system is provided.
• the sensor system 59 is calibrated with fluids of know viscosities at specific temperatures.
• a first sensor 54 is placed upstream of a flow restriction and a second sensor 56 is placed downstream.
• the pressure differential decreases between fluid pockets 53 and 55.
• the fluid level in pocket 53 also decreases with respect to the fluid level in the fluid pocket 55.
• the output of sensor 54 in fluid pocket 53 decreases with respect to the output of sensor 56 in fluid pocket 55.
• the difference between the outputs of sensors 54 and 56 is directly proportional to the viscosity of the flowing fluid.
• the liquid sensors 20 and vapor sensors 30 can also be used to detect the formation of insoluble coolant/water concentration in fluids.
• Liquid array sensors spaced less than 75 microns apart or array sensors spaced greater than 500 microns apart or wire rod sensors spaced greater than 1 mm apart are typically used to detect insoluble coolant/water. For example, when coolant leaks into oil, coolant/water dissolves into oil to about 300 — 500 ppm concentration, depending on variables such as, dispersant additives, basestock composition, temperature, etc and is undetected by the sensors.
• coolant/water droplets form in the oil and, depending on the operating temperature, water evaporates from the oil into vapor.
• the droplets in the oil impact the liquid sensor surface or the water vapor condenses onto the vapor sensor surface or between the wire rod sensors in the vapor, the droplets/water form a layer of coolant/water on the surface.
• the length of the adhered film exceeds the array line spacing or bridges of the wire rod sensor spacing then the sensor is electrically shorted and goes off scale. As soon as the coolant/water becomes insoluble in the fluid, the liquid sensor will go off-scale which indicates that water concentration is greater than 300 -500 ppm.
• the amount of water in the fluid to cause shorting of the vapor sensors depends upon the vapor array or rod spacing, i.e., the smaller the spacing, the less condensate is needed to short the array as well as the fraction of total system water that condensates onto the vapor sensor.
• a baseline can be established to compare the measurement if continuous monitoring of the vapor sensor is deemed necessary.
• the accumulation of soot in oils can be monitored by comparing the output of at least two of the liquid sensors.
• a filter or other means to separate the soot from the oil may be placed on top of the liquid array senor surface or around a liquid wire sensor so that only soot free oil can touch the sensor. At least one other sensor is not covered by the filter and is therefore exposed directly to soot containing oil. If the difference between the outputs of the filter covered sensor and the uncovered sensor remain unchanged with operating time, then the sensors are not detecting soot accumulation. If the uncovered sensor output increases with respect to the output of the covered sensor, then the increased difference between the senor outputs is indicative of, and proportional to, soot accumulation in the fluid.

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• Investigating Or Analyzing Materials By The Use Of Electric Means (AREA)
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• 2002
  • 2002-09-30 US US10/260,754 patent/US7043967B2/en not_active Expired - Lifetime
• 2003
  • 2003-09-22 AU AU2003267293A patent/AU2003267293A1/en not_active Abandoned
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