Novel Methods for Real-time in situ Analysis of Lubricants, Coolants, Hydraulic Fluids, and Fuels for Condition Based Maintenance

A novel real-time, in-line, optical multi-sensor has been developed to monitor contaminants in hydraulic fluid based on industry-accepted principles of laser obscuration particle counting and infrared spectroscopy. The device concept has been proven inlaboratory testing wherein particulate contamination was accurately measured and coded according to the NAS 1638 classification system, and dissolved water was measured to better than ,b25ppm in hydraulic fluid. Additionally, the capability of the deviceto monitor dissolved contaminants, e.g., chlorinated solvents and rust inhibitors, has also been clearly demonstrated. The resulting optical multi-sensor provides a compact, robust, reliable, and cost-effective monitoring capability for hydraulic fluidcontaminants. This system allows real-time monitoring and alerts for each species of contaminant, a read-out of contaminant level, and computer acquisition of diagnostics and monitoring history. Collaborations have been established with OEM and COTShardware producers for a rapid and low cost transition to a manufactured, commercial-ready device within the timeframe of the Phase II development program. Execution of the proposed Phase II program will result in the development of an effective hydraulicfluid contaminant sensor for condition based maintenance of submarine hydraulic systems. This will lead to an immediate market for monitoring systems for US Navy submarines. Additional applications include monitoring hydraulic fluid for condition basedmaintenance of commercial and military surface ships and aircraft, as well as heavy machinery in the manufacturing, construction, and power generation industries. The optical multi-sensor is expected to find markets wherever hydraulic fluid is used as theprimary working fluid in high value machinery.