The issues with Conventional Filtration, and the reliability of Hydraulic and Lubrication systems.
The Problems caused by “Aggressive contamination” in our critical systems.
The Historical Limitations and problems introduced by Conventional Filtration.
“In Short, MAGNOM Technology has proved to be and will continue to be ‘the best value component’, that can be fitted to any system prone to ferrous debris contamination!“
Techno Support, have a long-standing relationship with Magnom Corp, and have supplied and represented our products across the Japanese geography for many years,
Techno Support have a wealth of knowledge and experience supplying Magnom’s unique technology into the Automotive and Industrial markets.
Solutions for Your Problems
If your company is experiencing any fluid contamination problems, and you would like to source a solution, Techno Support & Magnom Corp, would be very happy to assist and help you, and support the specification of a solution to any ferrous contamination issues being experienced with your systems.
Techno Support are able to advise users and customers of Magnom’s Technology benefits,
They have a long history of supplying our solutions into the Japanese market and can advise on Magnom solutions available for all fluid systems… from ‘On Vehicle’ OEM applications, to production and process use.
Be it in Hydraulic, Lubrication, Water, Gas and Process fluids used for Production Applications…
Essentially any fluid or gas, experiencing ferrous particulate, ferrous oxide, magnetite, black powder contamination, in fact any ferrous based contamination, that is causing problems for your or your customers products, systems and/or processes…
Solutions for :- Full Flow, Suction, High Pressure, High Volume, Differential Pressure critical fluid or gas systems.
Techno Support have been our valued historical partner in Japan, and will be please to assist with a Magnom Solution to your problems, that is and has been globally tested, proven, reliable solution, a true value add solution for your critical systems.
We are pleased to see the new Techno Support promotion and wish to continue to support them and their customers across Japan.
Extending the operational life – protecting and improving our sensor functions,
Inductive & magnetic sensors rely on their magnetic field gradient being interrupted or distorted, thus inducing a signal / imposing a hall effect change to the flux gradient.
These sensors rely on accurate positioning and consistent signal recognition,
Because these sensors have a Magnetic field emanating from their signal generator, this part of the probe/sensor can become coated with and influenced by the ferrous/ferromagnetic debris, circulating within the fluids, that is attracted to it.
This can then corrupt the validity of the sensor, and result in inaccurate signal recognition (position) and timing, even during early stages of use.
In systems that are immersed in fluids, such as hydraulics, transmissions, etc… these systems contain ferrous debris in significant quantities, typically present in three distinct stages :-
Despite cleaning during production, contamination is frequently built into the components and the system ‘During Manufacture’.
During Break-in (Running In) high levels of contamination is present, as the components/systems contact surfaces bed into each-other.
During normal system use, wear and tear takes place, generating microfine ferrous contamination.
It is very difficult for conventional filtration, i.e. barrier/media filtration cartridges to address this problematic contamination and effectively remove this fine ferrous particulate from fluids,
Explantation…
In mechanical systems, the ferrous contamination is typically very small in size (typically sub 10 micron), this is because it is generally generated from hardened… bearing & contact surfaces throughout our systems, subsequently these surfaces do not shed their material easily,
The ferrous is thus torn from these surfaces in tiny particles, which are not only small, but super hard and super sharp.
Conventional filtration is rated by pore size, so any particulate smaller that the pore size simply passes through the filter media (imagine a sieve screening out say husk from flower etc).
It is possible to produce microfine conventional filtration,
But it would be so restrictive to fluid flow, very costly and so large in size, (to provide sufficient surface area for fluid flow), that it is a non viable proposition from a space-claim, high purchase cost and function perspective, to be a viability for our fluid systems,
So a compromise is struck for/with all of these factors.
Being typically smaller than the pore size of conventional filters, these ferrous particles can recirculate through them, and thus causing not only further system & component wear and further contamination generation, but the contaminating of our sensors blinding/corruption of our system sensor signals, and thus incorrect system function and indeed failure.
Just such a simple issue with a sensor, can at best dramatically affect system functionality or indeed stop the whole system.
This is hardly surprising…
When you consider that 80% + of the systems/products we produce globally are made from Steel & Iron!
Solution :-
Fortunately a solution is possible, and readily available.
Since the main protagonist in this problem is ferromagnetic, it makes complete sense to use magnetics to solve the issue,
But a magnet alone will not resolve our issues, as the humble magnetic drain plugs fitted to most systems demonstrates.
As these magnetic plugs are just a random attempt to address the performance shortfall of conventional filters (otherwise why fit them in the first place), but they clearly demonstrate that our industry recognises the existence of the conventional filter issues, and has done for decades,
There has just not been a technology available to resolve these issues once and for all… systematically.
Until Now!
A technology developed from the high performance racing industry, and used in Formula 1 since 2007, is now being adopted and used by Major OEM’s worldwide, is available to the mass market, and is clearly demonstrated to resolve numerous issues caused by contamination left in circulation by conventional filtration, and experienced in & by our systems.
Described by its designer as “ Just a very novel was to filter fluids and gasses using clever magnetic flux gradients”
Its called ‘Magnom’ (Magnetic Oil Module), and is tested and demonstrated to remove the microfine ferrous in our systems up-to 100% efficiently, single pass… and does not discriminate by particle size, be it 1 micron or 1 mm + in size.
It is non restrictive to fluid flow, even when full of collected contaminants, and is Bi-Directional,
Which means…
For the first time, efficient and effective filtration can be employed on the suction side of a Pump, and also in the bi-directional circuit of a hydrostatic system, almost anywhere in the system, where protection is required, and value can be delivered for the user.
Thus removing the damaging and problematic contamination, that causes problems with our system sensors, as well as the other related damage this highly aggressive particulate causes.
As we become more reliant on sensors, and employ more and more of them in our electronically controlled systems, this becomes a growing issue for us all.
The reliability issues caused by the sensors own magnets harvesting ferrous particulates in the fluid/systems become a greater issue for us, so its fortunate a low cost solution is available to us.
As is often the case… what is adopted in the extrema environments like Formula 1 today, becomes employed in our everyday products tomorrow.
Solenoidal pilot valves…
As we move to remote control (typically joy stick) then we are also more reliant on solenoidal pilot valves.
Particularly in Hydraulic systems, it will be clear to most engineers that :-
These electrical pilot valves, do not have the power of the hydraulically actuated pilot valve, so the very same hard metallic particulate can easily jam these valves, as they have considerably less sheer power of their hydraulic cousins.
Used in conjunction with and dependant of the proximity sensors, the use of this new magnetic technology can deliver benefits for both components, as well as the system as a whole.
Why remove some contamination to a particle size?
When you can remove all of the most aggressive and damaging contaminant, irrespective of its size?
Not just bi-directional & non restrictive… Magnom technology can also hold approximately 40 X more contamination than conventional filters… ‘size for size’.
Prevent Hydraulic and lubrication system failures!
To truly understand the true benefit offered by Magnom Technology :-
I often ask fellow engineers to just forget the inherent limitations of conventional sieve filtration for a moment, as I would not want any previous experiences to limit the thought process in understanding the unique performance & benefits offered by the Magnom proposition.
Essentially conventional filers are sieves, and are size discriminate/filter by particle size!
But in our systems…the particulate/contaminant size is not the actual threat,
eg a 10 micron particle of say fibre offers little threat when compared to say… a 10 micron particle of high carbon steel.
But a conventional filter treats these materials as the same, because it only addresses size and not the threat posed to our systems!
Our history in the treatment of fluids here at Magnom teaches us something very import and very obvious in hind sight.
85 +% off all industrial and commercial products produced globally are manufactured from steel and iron.
So it is perhaps no surprise that the majority of damaging contaminant trapped in products/fluid systems during manufacture are steel and iron!
Also during the break in (running in) process the contact surfaces that are breaking in against each other are predominantly high carbon steel!
Again… normal wear and tear experienced during system use, high carbon steel particles are again produced and are circulating in the fluids.
This aggressive contamination is responsible for the start of the “Chain Reaction of Wear” and subsequent catastrophic failure!
To quote;- Jim Fitch of Noria :-
“The worse things get,
the faster things get-worse”
So!
We do not have to be particularly well informed to understand that these super-hard & super-sharp high carbon steel contaminants are the greatest threat to the health and availability of any fluid system (its essentially bits of the system killing the system itself),
These high carbon steel contaminants are also very small (typically sub 10 micron)
this is because they are torn from hard contact surfaces, these surfaces don’t shed material easily. so they are torn from these contact surfaces as very small particles,
Having been torn off they are also angular and very sharp.
So it makes sense to treat these contaminants as the primary threat to our systems,
be they industrial lube, or say hydraulic systems or indeed Formula 1 race systems.
What ever the system Magnom offers a truly unique strategic answer to this 80 +
year old problem.
A problem that has been largely ignored while the only solution available was a sieve or a magnetic drain plug!
In-fact think about it… why would OEM’s & system designers fit magnetic drain plugs… if conventional filters do the job we need them to?
Magnetic plugs simply would not exist, if conventional filtration were capable of removing this damaging material effectively.
The Proposition…
Simply!
Ideally remove the greatest threat to the system, ‘absolutely’ before the systems pump!!!
i.e. Before it is delivered to the valves and the rest of the system by the pump, causing expensive unnecessary and expensive damage…. on the return to the reservoir ‘after the damage is done’ on its journey through the critical components in the system!
In achieving this MagnomTM brings a host of performance and health benefits to these
fluid systems as a whole!
Longer equipment life, reduced maintenance/repair, higher system/product availability, to work for us.
Also with the Magnom product range you can strategically protect critical components and operations at any location in the system ‘high or low pressure’ without fear of cavitation or flow restriction and bidirectionally (flow can be in either direction).
Have initiated a series of validation testing and analysis, on customer HEAVY DUTY rough service mining equipment, to demonstrate the effectiveness and value of using MAGNOM technology.
Along with the added value the technology can deliver to customers and end users, here are details outlining the fantastic results seen during evaluation and customer benefits experienced.
Magnom Corp are very excited about the new partnership with ‘Kleen Oil’ Colombia, and to also see their test results reflecting the same benefits, seen world wide across many industry applications, from using this innovative technology.
First Results
Two months after having installed the MAGNOM Technology in ARGOS equipment,
When the service interval was reached and the ‘oil filter’ on their BUCRUS RH40E SHOVEL.
It was immediately possible to visually see the accumulation of aggressive metallic particulate removed from the oil, evident in the core of the Magnom filter unit, as can be observed in the images below.
When checking the Magnom Unit (magnetic filter) large amounts of damaging ferrous particles could be easily seen, imagine this debris recirculating around the system ‘time and time again’ unable to be removed by the conventional filters?
ARGOS consulted their CAT dealer, about the condition of the engine that had been repaired 3 months earlier.
Not only had the Magnom technology removed all of the ‘Break-In’ debris from the fresh engine, but also protected the engine from a mistake during re-build, causing even more ferrous generation.
Fortunately the dealer was able to correct the fault, and the engine was able to continue operation, without further damaged,
In this case, the MAGNOM magnetic filter not only protected a very valuable engine from the highly aggressive iron particles in the oil, by reducing friction & attrition in the engine, but importantly served as a prevention of failure, ‘and an early warning indicator’ for the customers engineers.
Saving a very valuable engine & machine from damage & failure, and also saving revenue, but also enabling the machine to remain available and to continue to work, generating revenue for the customer/user.
A Major Off Highway Machine & Equipment OEM, deciced to try a new concept in filtration, to protect the hydraulic pump & system Pre-Pump.
The vehicle selected for a second phase of testing of the Magnom 2” suction unit “PumpMate” was a ‘Brand New’ production vehicle straight from the factory production line.
This and other test vehicles where assessed and analysed in a combined and concurrent test program that was to replicate normal running conditions for a period of 1250 hrs
Following successful testing of a 2” PumpMate on a prototype machine, the second phase test was initiated to demonstrate what benefits Magnom technology could achieve on a new, optimally cleaned Company production product.
Following the 1250 hr test the machine was returned to the work shops for removal of the test unit and further investigation work.
The Magnon unit was removed by Company technicians and prepared for product disassembly by Magnom staff.
The internal magnetic core was sent for independent testing by the UK Government contractor Qunetiq
Sample of contamination removed from the PumpMate, the majority being sub 10 micron in size
Even preliminary inspection of the test unit indicated, that the test Magnom had indeed performed extreamly well.
On closer inspection, a significantly higher volume of harmful contaminant than was expected by all, was observed trapped within the cores of the Magnom 2” Pump Mate suction unit.
One surprising aspect of these findings is that, so much harmful contamination had been removed pre-pump from a Brand New & “Clean” production machine.
Clearly the collected contamination consisted mainly of “Built in” Manufacturing debris & contamination generated during the “Break-in” process.
This image gives us a very strong indication Of the single pass efficiency Of the Magnom suction technology
Question!
Would any hydraulic equipment manufacturer or operator allow material such as this to be consumed by the systems pump, causing major damage to the Pump its self and then distributing this contamination plus the pump wear material throughout the entire system…
“IF IT’S PREVENTION WERE POSSIBLE”?
Never before has it been possible To arrest this chain reaction of wear Pre-pump, thus protecting the entire system and bringing about benefitsnever previously thought possible, and uniquely such is the capacity of the PumpMate, it is designed to be a “FIT & FORGET” installation for most systems.
Please see independant testing and further evaluation of this amazing product here:-
What do we know to be ‘The Greatest Threat‘ to reliability of a Fluid Power or Lubrication System :- i.e.?
———————————————————–
Question!
What causes failure of an otherwise
healthy fluid system (apart from excessive heat)?
Answer!
Microfine Contaminants, super sharp and as hard as any component/material in the system, circulating and re-circulating around that system, Flowing between the working surfaces of critical components! Causing wear and degradation of critical components. Threatening the system from within!
Ferrous!…. Steel & Iron… From…Manufacturing, Brake in, and General Wear & Tear
Effectively bits of the system itself… killing the system,
The proposition is a simple one!
1,Remove the worst threat to a system ‘ABSOLUTELY!!!’
2, In ‘Strategic locations’in the system that deliver the most benefit
3, Where it can have a massive impact on the ‘health’, ‘life’ and the ‘reliability’of the system.
4, And thus positively effect Customer Experience, Brand Confidence and ultimately Warranty!
Simply “Stop the Chain Reaction of Wear” From the outset !
And prevent the damage to and the generation of wear metals, from critical system components, such as the softer sacrificial metals… Such as… Aluminium, Bronze, Copper, Brass, & White metal.
WHY NOW?
Our fluid industry has become obsessed with conventional Sieve filtration as being the only solution, & this has…
Not changed for 80 + years!
Only now! do we have the technology availableto address this remaining problem!
As our industry moves to :-
1, Higher working pressures (5000 & 6000 psi >)
2, & Higher fluid velocities
3,& Closer working tolerances
4, Optimised system designs, rather than over engineered systems.
The need to resolve these historic issues becomes even greater…
REMEMBER!
The particle contaminant size is not important…
What its made of… and the threat it poses to our systems is!
“Stop the chain Reaction of Wear” ‘or Suffer the Consequences!’
