LifeSense hydraulic hose condition monitoring system

Two of the most common causes of hydraulic hose failure are internal fatigue due to impact cycles and external abrasion; combined, these account for over 80 per cent of field failures. In the past, many operations in the sector have chosen to minimise the risk of hose failure by replacing hoses on a fixed schedule. This standard practice can increase cost and generate waste.

With this in mind, some hose manufacturers have developed predictive formulae that consider time, pressure, temperature, the number of flex cycles, and other factors to calculate an approximation of expected hose life. Eaton's in-house lab testing shows most hoses that are replaced on a time-based schedule of estimated life had actually reached less than half of their safe useful life.

Eaton initiated a research project in partnership with Purdue University to effectively address the issue of hydraulic hose failure. The project sought to identify measurable, structural phenomena associated with hose deterioration over time, and develop the required technology to monitor them accurately.

Hydraulic hose condition monitoring system

This joint research determined that hydraulic hose failure is the final step in a consistent process that can be measured and therefore monitored to provide a reliable indication of an approaching end-of-life condition. The result is the LifeSense intelligent hydraulic hose condition monitoring system that detects failure-related events within a hose and provides advance notification the product is approaching the end of its useful life.

Eaton's LifeSense system is based on the fact certain properties of a hose change as the hose approaches failure. Eaton found that by periodically comparing samples of these properties to a baseline gives a highly reliable indicator of imminent hose failure. Each hose fitting is equipped with a sensor that continuously monitors hose conditions via electrical signals, which are submitted to a hose diagnostic unit that interprets the data.

The hose diagnostic unit (HDU) runs on 12V or 24V DC and can monitor up to 11 hose assemblies. A range of standard wire cable lengths is available to accommodate different applications, running from 3m up to 300m. As the hose assembly approaches the end of its useful life, LifeSense detects events occurring within the hose that have been shown to lead to failure and then provides notification to the user. This notification is provided with enough time to replace the hose during planned maintenance prior to failure, which reduces downtime and, in particular, unplanned stoppages.

Advanced system monitoring

LifeSense is also available in a wireless option with a gateway that can monitor up to 100 hoses with a 433Hz frequency communication protocol. The sensors, which have a greater than six-year battery life, continually monitor the hose and the gateway transmits operating performance data to secure server once per shift (every six hours); should an issue arise, the gateway transmits data immediately. Eaton's LifeSense web portal offers advanced system monitoring providing maintenance teams access to specific data such as hose installation date, connection status, trend reports and diagnostics management.

Tests have shown that assemblies safely remain in service for far longer; up to 50 per cent more service life can be expected. Real-time monitoring of the hose can also make the workplace safer, more productive and more profitable; moreover, concerns about idled equipment, environmental clean-up, collateral damage and personal safety are also reduced.

Follow the link to learn more about Eaton's LifeSense intelligent hydraulic hose condition monitoring system.