Combining Inspections with Lubricant Analysis - The ID-600/MAINTelligence Monitor System from DMSI

There is a wealth of information contained in every oil sample. Lubricant analysis laboratories can extract information on the physical properties of the lubricant, level and type of contamination, and indications of abnormal wear at the sliding and rolling surfaces within the machine itself.

This information by itself has great value in determining the condition of both the lubricant and the machine it is operating within. However, additional data is needed to help determine the root causes of many problems.

Traditionally, collecting this information has been difficult. The ID-6100 from DMSI helps to automate the collection and management of inspection data so it can be incorporated into the decision making process. Changes in the operating state of a machine can have a substantial effect on the results that come back from the lab. Even more importantly, the lubrication schedule within the plant and the types of additions and changes made to the working lubricant within the machine will have a profound effect on lubricant analysis results.

Unfortunately, this data is often not readily available to the lubricant analyst. A change to the lubrication schedule (i.e., oil changes, top ups, addition of anti-oxidants or other “sweeteners”) or the operating state of the machine can result in erratic oil trends. These “jumpy” trends seemingly defy explanation - unless the information from the lubricant scheduling program or other condition monitoring data can be viewed at the same time as the lubricant analysis results.

Traditionally, lubricant level checks, top-ups, replenishment of additives, etc. have been performed during lubrication “rounds”. The data collected, if any, is either noted on a clipboard form or (at best) entered into a simple spreadsheet or database. Also, data concerning the operating characteristics of the machine are similarly noted on the operator’s log sheets. It is usually difficult to bring these data sets together to allow the
analyst to view lubricant condition indicators within the context of the lubricant management program.

Over the last ten years, DMSI has established itself as a leader in the design and development of software tools for the lubricant analyst. The company’s software tool , LubriScan, has been used to implement and manage lubricant analysis programs in hundreds of industrial, military and transportation companies. For many of those companies, DMSI has faced a common problem - how to effectively integrate lubricant management, machinery operation and lubricant analysis data, to maximize the effectiveness of the lubricant analysis process.

MAINTelligence Monitor and the ID-6100 was introduced in 1998 to solve this problem. MAINTelligence Monitor is a new 32-bit software system that integrates lubricant analysis and machinery operations data. The ID-6100 is a rugged, pen-based handheld computer designed for the collection of machinery operation and lubricant management data.

The ID-6100 deploys a versatile data collector with 2 internal Type II PC card slots, several available bar code and memory disk options, and interfaces to RS-232-based instruments.

The ID-6100 system software was designed with the lubricant specialist or maintenance professional in mind. The unit has been successfully applied in a number of industries, including aluminum smelting, mining, marine, pulp and paper and plastics.

Used in partnership with MAINTelligence Monitor, the lubricant specialist has an integrated database of both lubricant sampling and lubricant scheduling information.

The ID-6100 can also be used to integrate lubricant sampling information with other condition monitoring parameters. Interfaces to infrared temperature guns and vibration “pens” have been added to the system, allowing the instrument to be used as a meter that measures and records temperature, velocity and high frequency bearing values.

The unit recognizes both wand-type and integrated-laser type bar code scanners. Other tagging methods such as touch buttons and RFID tags can also be used by the system.

Pick lists are used in many inspection processes. The ID-6100 allows up to 32,000 selectable items in a single pick list. The ID-6100 data collector is the perfect companion to MAINTelligence software. The following features to make the cross-comparison of lubricant sampling and other condition monitoring data easier.

  • Single data retrieval interface. Whether you are acquiring data from the ID-6100 instrument, other lubricant analysis instruments or from one of the many analysis laboratories that MAINTelligence Monitor supports,
    the method of acquiring the data is the same.
  • Report editor allows you to build reports that allow lubricant analysis, lubricant management and other
    condition monitoring data sets to be displayed simultaneously. Reports can have multiple graphs, images and tables on a single page.

MAINTelligence Monitor and the ID-6100 are a potent combination in the implementation of an effective integrated lubricant analysis, lubricant management and inspection program.

For more information see the DMSI Website.

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