On-line lubrication monitoring and fault diagnosis of steel hydraulic system, analyzing the threat of water intrusion

　　With the continuous development of industrial production, steel mills as an important metal processing enterprises, the operating state of its hydraulic system equipment has a crucial impact on production efficiency and product quality. The traditional hydraulic system equipment monitoring mainly relies on regular manual inspection and maintenance, this method has some shortcomings. Manual inspection is not only time-consuming and laborious, but also easy to miss problems, resulting in equipment failure and production interruption. Due to the complex working environment of hydraulic system, it is easy to be affected by water, pollution, high temperature, high pressure and other factors, so a more accurate and real-time monitoring method is needed to ensure the stable operation of equipment.

1. Abnormal lubrication of hydraulic station of rail and beam factory

The lubrication dilemma of hydraulic station of 1.0 rail beam factory

The oil film bearing in the rolling mill production line is the key component, which is used to support and protect the normal operation of the bearing. However, due to the special nature of the production environment, such as the work area may be affected by water or moisture, the mill line is prone to water intrusion problems

　　■ Oil viscosity reduction: After water, the viscosity of hydraulic oil usually decreases. This can lead to reduced flow in the hydraulic system, affecting the performance of the system.

　　Oil emulsification: Some lubricating oil may be emulsified in the presence of water, which makes the conditions for establishing oil film more harsh, further reducing the lubrication performance of bearings.

　　■ Oil deterioration: If the system is invaded by a large amount of water, the lubricating oil may be emulsified in large quantities, or even seriously deteriorated, so that it cannot effectively lubricate and protect.

　　Bearing wear: Due to the intrusion of water and insufficient local lubrication, the wear of the bearing is intensified during the rotation process, which will lead to the shortening of the life of the bearing, and even cause the bearing to be damaged and scrapped.

　　■ Possible causes: There are many reasons for the water inlet problem of the oil film bearing, including the equipment seal is not tight, the working environment humidity is high, the equipment aging wear, improper maintenance, water pollution, cooling system failure.

　　Second, rail beam factory hydraulic station predictive maintenance solutions

　　INZOC online oil monitoring system is committed to providing enterprise customers with intelligent solutions for efficient and accurate monitoring. It has shown outstanding advantages in the application of a rail and beam factory hydraulic station. The core advantage of the system is real-time monitoring and analysis of key parameters of hydraulic oil, while closely integrating INZOC intelligent lubricating oil cloud platform. For enterprise customers to bring significant benefits and value.

　　此方案通过监测含水量、饱和度和污染度等重要参数，能够准确预警液压系统可能存在的问题，如水分入侵。以往，这些问题可能只能通过定期人工检查或等待设备故障才能察觉，而现在，我们能够在问题加剧之前提前发现，从而有效地避免了设备损坏和生产中断。

　　2.0 某轨梁厂液压站润滑监测与数据诊断

　　当液压系统中进水导致油液乳化时，液压油会变得浑浊、粘度下降，可能产生泡沫和降低润滑性能，增加磨损和腐蚀风险，同时也影响冷却性能和电导率。这种情况需要及时处理和维护，以避免对液压系统性能和可靠性造成不利影响。

　　现场工程师对液压站设备中的46号液压油进行取样，该设备油液可见浑浊(如下方左右图所示)，正常的油液清澈透亮(如下中图所示)，说明该油品发生乳化现象。

　　▲ The left picture | comes from the Internet; The right picture | hydraulic station site sampling oil

　　INZOC online oil monitoring system is committed to providing enterprise customers with intelligent solutions for efficient and accurate monitoring. It has shown excellent advantages in the application of hydraulic station in a rail and beam factory, and has brought significant benefit value to enterprise customers.

　　■ Real-time monitoring and warning: INZOC online oil monitoring system enables real-time tracking of hydraulic equipment status by continuously monitoring key indicators such as water activity (saturation), water content and contamination degree. Among them, the system can not only detect a momentary spike in data, but also be able to capture a gradual upward trend. This capability allows the system to warn in advance of possible equipment problems, such as equipment failure or sensor poisoning, providing technical operations personnel with valuable early warning information to help avoid potential production disruptions or damage.

　　■ Accurate analysis and problem diagnosis: Through data analysis on INZOC's intelligent lubrication and oil cloud, INZOC's online oil monitoring system not only shows the existence of problems, but also provides specific data support. As shown in the figure below, the system and platform can visually show the trend of water activity (saturation) in the oil rising up to 100% and the water content exceeding the preset value, thus excluding other possible causes of abnormal indicators. At the same time, the system also takes into account the impact of water on pollution levels, so it can capture the rising trend of pollution levels, further demonstrating the possibility of water intrusion in the equipment, providing accurate problem diagnosis.

　　▲ Oil data before dehydration (intelligent lubrication · Oil cloud mobile terminal)

　　As shown in the following figure, after the equipment was dehydrated by emergency measures, the oil saturation was reduced to about 29%, the water content was reduced to about 45ppm, and the pollution NAS level was reduced to level 3 and returned to normal value.

　　▲ Oil data after dehydration (intelligent lubrication · Oil cloud mobile terminal)

　　When the hydraulic oil monitoring data shows abnormal, INZOC intelligent lubrication oil cloud platform will automatically associate the alarm, send the work order to the operation and maintenance personnel through the mobile phone, web or email reminder, in time to contact the engineer on-site inspection, and quickly take countermeasures to the equipment, not only to recover the possible major losses, but also to improve the reliability and service life of the equipment.

　　■ Reduced maintenance costs and risks: INZOC's online oil monitoring system benefits not only from accurate monitoring, but also from reduced maintenance costs and risks. By early detection of equipment problems, technical operations personnel can take preventive maintenance measures to avoid production stagnation and high maintenance costs caused by sudden failures. In addition, the system also helps to extend the service life of the equipment, improve the reliability of the equipment, and further reduce the operational risk of the enterprise.

　　■ Increase production efficiency and sustainability: INZOC's online oil monitoring system helps increase productivity through continuous monitoring and early warning of problems. Reduce maintenance downtime and production disruptions, ensuring stable production line operation.

　　INZOC's intelligent online oil monitoring solution does not stop at the data acquisition level, but also combines digital twin big data analytics and iot cloud platform to enable failure prediction. Through in-depth analysis of historical data, the system can identify trends and patterns in equipment performance, further improving the accuracy and efficiency of equipment maintenance. This enables businesses to adopt a more proactive maintenance strategy, reducing unplanned downtime and increasing productivity.

　　Smart Match's intelligent lubrication monitoring analysis is an efficient and superior solution that provides a key competitive advantage to rolling mills and other corporate customers. Through real-time monitoring, early warning, rapid response, as well as data analysis and the application of the Internet of Things cloud platform, the solution can not only ensure the reliability of equipment, but also help enterprises save maintenance costs, improve production efficiency, achieve scientific management, and provide strong support for the sustainable development of enterprises.

　　2.1 Online oil monitoring system deployment case

If you need:Steel hydraulic oil monitoring system，Please contact us. Wise match, well-known domestic oil monitoring system provider!