Method and system for failure prediction using lubricating fluid analysis
Methods and systems for failure prediction using analysis of oil or other lubricant. Raw data about feature(s) of each of a plurality of particles filtered from a fluid sample are used to categorize each particle into one of a plurality of categories, each category being defined by one or more of: chemical composition, size and morphology. Particle physical characteristics in each category are quantified to obtain a set of categorized data. The categorized data are compared with historical data. Results of the comparing are evaluated to generate a prediction of any failure or mechanism of failure.
1. A method for generating a failure prediction for an engine of an engine type, the method comprising:
receiving particles filtered from lubricating fluid of the engine;
using X-ray spectroscopy, analyzing the particles and producing raw data relating to the particles, the raw data including chemical compositions of individual particles;
using one or more processors and the raw data:
categorizing the particles into categories to generate categorized data, at least one of the categories being a chemical composition category;
comparing the categorized data with historical data associated with the engine type;
generating the failure prediction based on the comparison and a number of the particles in the chemical composition category, the failure prediction being indicative of one or both of the following: when the engine is expected to fail and a mechanism of failure of the engine; and
generating an output indicative of the failure prediction.
2. The method of claim 1 , wherein:
the raw data includes sizes and morphologies of the particles; and
the failure prediction is based on the sizes and morphologies of the particles.
3. The method of claim 1 , wherein the particles include particles smaller than 30 μm in diameter.
4. The method of claim 1 , wherein the particles include particles having a size between 0.5 μm and 1600 μm in diameter.
5. The method of claim 1 , wherein the chemical composition category is defined according to a particle source within the engine.
6. The method of claim 5 , wherein the particle source is a bearing of the engine.
7. The method of claim 1 , wherein the comparison comprises at least one of a calculation of deviation of the categorized data from the historical data, and a calculation of variation of the categorized data from the historical data.
8. The method of claim 1 , wherein the comparison comprises at least one of a comparison of the categorized data in each of the categories to the historical data, and a comparison of a composite of the categorized data to the historical data.
9. The method of claim 1 , wherein the failure prediction is indicative of premature wear of a component of the engine.
10. The method of claim 1 , wherein using X-ray spectroscopy includes using X-ray fluorescence.
11. The method of claim 1 , comprising filtering out the particles from a sample of the lubricating fluid, wherein the sample has a volume of 25 ml or less.
12. The method of claim 1 , wherein the particles includes at least 1000 particles.
13. The method of claim 1 , wherein the chemical composition category represents a composition zone within an alloy system.
14. The method of claim 1 , wherein the particles include non-metallic particles and the raw data includes data relating to the non-metallic particles.
15. The method of claim 14 , wherein the particles include metallic particles and the raw data includes data relating to the metallic particles.