Global OEM Independent Testing & Evaluation of Filtration
PROJECT SCOPE :-
Evaluation of Magnom performance versus conventional suction strainers & – Evaluation of total system cost.
The Magnom PumpMate is :-
“Far Superior at Removing ferrous particles from the hydraulic fluid than conventional suction strainers”
Summary…
Compelling results for further OEM adoption of Magnom PumpMate
Conclusion :-
From historic experience and exhausting testing and analysis of these magnetic filtration products.
The Magnom filter is far superior at removing ferrous particles from the hydraulic fluid compared to the conventional suction strainers and should become a group standard. Recommendation: Introduce Magnom PumpMate to machines as part of NPIP programmes; replacing the conventional suction strainer.
A world leading OEM approached Magnom Corp, to develop a filtration solution for the transmission systems produced and used by the company,
The objective/desire was to improve the life of the transmissions and if possible increase the performance and availability of the systems,
The big as was… to also reduce the servicing frequency of the systems, and thus reduce the ownership cost to the end user.
Product development were confident of increasing the transmission life using Magnom magnetic filter technology, and delivering at least some of the additional benefits desired,
However the end results… exceeded the expectations off all those involved with this development project,
Please read on!
Space envelope for suction unit proposition, information/product sample provided by the OEM
The CAD designed prototype proposition
Working within the space envelope provided, And with an acceptable flow area, Five individual Magnom core units were selected Maximising the contaminant capacity of the solution within the space envelope.
We have located the fluid entry port of the solution at the lowest point in the design, To prevent the cavitation issues experienced with the existing strainer.
Actual Prototype Product
It was envisaged that Magnom could add significant benefit in, fluid clean up following production and assembly, run/break in and continuous
wear and tear during normal use.
From our wealth of experience in the transmission environment, Magnom where/are confident of demonstrating the added value that could be gained
form incorporating Magnom in the OEM transmission systems.
Initial results!
The first vehicle to provide results from testing, completed 759 hours before the operator expressed concern with the performance of the transmission,
The senior development engineer confirmed that the transmission had significantly overheated,
and that it was so overheated, fluid was coming out of the filler and breather.
This had been due to the incorrect wiring of a temperature sensor.
It was decided that the transmission should be removed from the vehicle and returned to the Factory and stripped for analysis.
Surprisingly, even though the transmission had been subject to this excessive heat (the torque converter had turned blue),
all of the internal components where within tolerance,
The Magnom prototype was removed for inspection and a further new unit was provided for the continued evaluation in the Magnom in the same transmission.
The transmission we reassembled with no need for ANY new components and refilled with fresh oil
The OEM’s development engineer commented,
“usually the white metal bearing in the pump is the first thing to indicate issues in the transmission,
but there is no sign of this wear on this or the rest of the pump,
It is in better condition than we would expect to see on a vehicle, that had not had any failure at all that had covered the same number of hours as the test transmission”
I inspected the pump for myself, there was only an indication of high spots on the bearing where the surface was starting to bed in, Truly amazing!
This is I believe testimony indeed to the effectiveness of Magnom, given the attrition suffered by the test transmission.
The test Magnom prototype was removed by the OEM team and weighed so as to ascertain the weight of the captured contaminant,
the actual amount of contaminant contained within the Magnom was 20 grams.
Samples of the contaminant removed from the fluid ‘pre-pump’ by the Magnom’s core, where also so taken for analysis
Analysis was performed thus;-
A small sample of the contamination was washed in a chemically pure solvent and filtered through a 1.3 micron filter,
viewing the residue with the flat field microscope.
Observations,
Most all the debris was ferrous, with just one or two grains of silica in the sample.
The ferrous material is mostly in the 5 micron to 50 micron size range with some larger particles,
up to say 120 microns across
The larger lumps are mainly flat’ish rather than granular and are irregular in appearance.
The really interesting point that these results highlight is that, ALL of the contamination stopped from entering the pump and transmission system by the Magnom, would have passed straight through the 125 micron strainer currently being used in the transmission.
Conclusion,
The Magnom Magnetic Core Technology performed extremely well in this comprehensive and arduous trial.
Quantification of the benefits gained from the adopting of Magnom technology into this application fall under a number of potential headings;-
There apparently being little benefit realised from the use of the current 125 > micron strainer.
The pump would (with the conventional strainer) have digested ALL 20 grams of super hard, super fine ferrous contamination removed by the Magnom, as would any other critical components in the system, situated down stream of any conventional filtration.
It is fair to assume, that the use of Magnom Technology will deliver on the original stipulations requested by the OEM, and as a added benefit have a very significant beneficial impact on the service life of the conventional filtration and would also keep the system more effectively protected, while the conventional filter was in by pass mode, during start up, cold conditions and when blocked etc.
This protection could have a very significant impact on warranty cost and customer satisfaction, and could help demonstrate to the customers
distributors and indeed end users that company is adopting new technologies/solutions on an ongoing basis, to benefit them directly.
Moving forward,
The rebuilt transmission has now been refitted with the prototype Magnom and is being put back on test alongside the other test vehicles equipped with the Magnom transmission prototype.
The data gathered will further reinforce decisions to adopt the technology on a wide variety of systems
Armed with this information we can start to better understand the total benefit of using the Magnom in applications across a wide spectrum of usage.
These include;-
Extended pump life/protection
Extended valve life/protection
Extended filter life/service
intervals
Extended transmission life,
Extended fluid life/ service
intervals
Reduction in warranty claims
The use of tighter tolerances in
the design and manufacturing process
Customer satisfaction(warranty
related)
Effective clean up of the system
following manufacture and assembly
Please return for more Magnom application and testing news
Magnom were asked by Rolls Royce to develop and produce a version of their magnetic separation technology, to fit in conjunction with the existing system design of the latest development of their Trent 500 Turbo Fan Jet engine.
This highly developed engine can be found in applications :- from Power Generation to the A340 Airbus used across the globe by all of the major airlines.
The Trent 500, like many other Turbo Fan jet propulsion power units has a gearbox,
This gearbox is driven by a quill shaft from the main rotor shaft,
The gearbox powers all
of the engines ancillary systems e.g. starter, generator, oil,
hydraulic & fuel pumps etc…
Gearboxes can be the main source of ferrous contamination, and given that the Trent 500 utilises a common oil lubrication system, it is essential to use every possible technology to prevent any migration of micro fine contaminants (especially hard and sharp ferrous particulate) from reaching the main rotor shaft bearings, (as these shafts and bearings can rotate at 1000’s of RPM),
The reliability of Rolls Royce engines is world renowned, Magnom Corp were grateful for the confidence shown by Rolls Royce, in both their Technology and technical ability, and for the opportunity to enable them to develop a solution for long term testing on actual Trent 500 turbo Fan engines.
The development Magnom units depicted here, has been on test in Spain, to prove benefit and reliability on the Rolls Royce power units.
More information will
be made available in due course.