Degradation testing for electromechanical components such as pumps, valves, and sensors involves a series of steps to identify wear and tear that could lead to system failure. The goal is to detect these signs of degradation early enough to replace the part and prevent system failure.
For pumps, degradation can be monitored by sensors. A study on gear pumps used an accelerated life test (ALT) to monitor the degradation state. The volumetric efficiency of the pumps was measured over time, and the wear clearances were recorded. As the wear gap increased, the flow rate gradually decreased, indicating wear degradation.
For valves and sensors, similar methods can be applied. The reliability of these electromechanical devices can be tested using tools such as failure mode and effects analysis (FMEA) or fault tree analysis (FTA). The scope of the test should be clear, realistic, and aligned with the design specifications and customer requirements of the device. Different types of methods can be used, such as functional testing, performance testing, environmental testing, endurance testing, and accelerated testing.
In addition to these methods, real-time wear debris monitoring technology can be used. This technology is based on the principle of electrostatic monitoring, which was originally developed to detect wear. Sensor data is usually downloaded to a PC-based analysis package for further processing and trending. The early detection of wear offered by this direct technique provides a range of benefits in several industries.
Once wear and tear are detected in electromechanical components, it is crucial to inform the user or maintenance team so that the part can be replaced before it fails and potentially causes system downtime or damage. This notification can be achieved through various alert systems:
Visual Indicator Panels.
Visual indicator panels, such as the 20030 Visual Indicator Panel for single-engine systems, provide a simple and direct way to alert users. These panels can display lights or other visual signals that indicate the status of the component, such as normal operation, wear detected, or immediate replacement needed.
Alarm Systems.
Alarm systems can include a range of components like sirens, speakers, strobe lights, and dialers. When wear is detected, these systems can trigger an audible alarm to alert nearby personnel. Strobe lights can also be used as visual alarm verification devices, drawing attention to the issue.
Voice Dialers.
Voice dialers, such as those offered by Viking Electronics, can be programmed to call pre-set phone numbers and deliver a recorded message when a component’s wear reaches a critical level. This allows for immediate notification, even if the user is not on-site.
Drive-Alert Detection Systems
Drive-Alert detection systems are designed to monitor vehicle movement or tampering with assets but can be adapted to serve as an alert system for wear detection in electromechanical components. They can provide audible chimes or trigger other actions like turning on lights or sending a signal to a control panel.
Combined Approaches.
In some cases, a combination of these methods may be used to ensure that alerts are noticed. For example, a visual indicator might be used alongside an audible alarm to ensure that the alert is noticed in a noisy industrial environment.
The choice of alert system will depend on the specific application, the environment in which the electromechanical component operates, and the preferences of the user or maintenance team. The key is to ensure that the alert is noticeable, reliable, and prompts timely action to replace the worn component.
In conclusion, degradation testing for electromechanical components involves monitoring the performance of these components over time, identifying signs of wear and tear, and alerting the user to replace the part before it leads to system failure. This process requires a combination of testing methods, monitoring tools, and alert systems to ensure the reliability and longevity of the system.
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