WearDetect with display – Gill Sensors & Controls

Oil debris sensors, continuously monitoring ferrous wear

Prefer to talk to one of our sales teams about our oil debris sensors and adaptors?

WearDetect oil debris sensors have been proven in use by world-leading manufacturers, to provide the earliest warning of the initial stages of machine failure. WearDetect is primarily used in oil based systems, such as gearboxes, across manufacturing and also by operators of critical and remote equipment. WearDetect can be used for stand-alone measurement, integrated into a larger PLC or SCADA system or used with Gill’s IoT platform for data collection, visualisation and alerts.

Key features

Real-time, continuous condition monitoring
Captures and measures both fine & coarse ferrous wear debris
Proven high return on investment by minimising unplanned downtime
WearDetect sensor data can be used to predict and schedule maintenance actions
Oil temperature or water presence measurement
No expert knowledge or training required to interpret results
Multiple thread adaptor options for easy installation
Data platform option provides insight into equipment health, straight to your device

Typical applications

Wind turbine condition monitoring
Automotive manufacturing
Industrial processes including paper & chemicals
Conveyor drives within distribution facilities
Condition monitoring in mining industries
Crane gearbox monitoring

Weight	2 kg
Dimensions	41 × 23 × 25 cm
Output	0-10V (analogue), 4-20mA (analogue), J1939 (CAN)
Mounting thread	1 1/2” NPT, 1 1/4” NPT, 1” NPT, 1/2” BSPP, 1/2” NPT, 3/4” – 16 UNF, 3/4” NPT, M20 x 1.5, M22 x 1.5, M24 x 2.0

Output
Mounting thread	Clear

Oil Debris Sensor with Display

Oil Debris Sensor

Oil Debris Sensor + IoT

Starter kit

WearDetect, oil debris sensors for continuous ferrous wear monitoring - more details

Designed & Manufactured by Gill Sensors & Controls in the UK, WearDetect oil debris sensors provide condition based monitoring that protects critical rotating assets by directly measuring ferrous wear within the equipment.

WearDetect provides an earlier view of wear trends in vital equipment. The sensor replaces the existing drain plug and wires into your existing PLC or SCADA system or Gill’s IoT platform. Alternatively, an ‘inflow’ adaptor arrangement can be used to install the sensor in the oil flow line, before any filters. The sensor captures and measures fine wear and coarse failure ferrous particles in order to allow machine wear trend insights.

Output protocol options for WearDetect include digital outputs (Modbus and CAN) or analogue outputs (0-10V or 4-20mA). There is also a local visual alarm option. The sensors are designed to suit most data collection devices such as dataloggers, PLCs and ECUs as well as Gill’s own IoT data platform.

WearDetect sensors have no moving parts and as a result are extremely reliable and accurate.

WearDetect Brochure

Wear Debris Monitoring on Low Speed Drives

An introduction to Wear Debris Monitoring in the industrial marketplace

WearDetect User Manual

WearDetect QuickStart Guide

WearDetect Starter Kit QuickStart Guide

View EU & UK Declarations of Conformity (DoC)

WearDetect Accessories

WearDetect oil debris sensors can be supported by accessories to assist with specific installation requirements.

WearDetect thread adaptors

Gill offer a range of thread adaptors for metric, NPT, BSP & UNF drain port types. Plug the WearDetect sensor into the sump using the relevant adaptor.

Inflow adaptor kit

An ‘inflow’ adaptor kit can be constructed using standard components to allow the WearDetect oil debris sensor head to be installed at a convenient position within the lubrication bypass circuit of the equipment. The inclusion of valves facilitates easy sensor inspection with minimal oil loss.

Inflow adaptor

An off-the-shelf ‘inflow’ adaptor will allow installation of the WearDetect, oil debris sensor probe at a convenient position within the lubrication bypass circuit of the equipment.

Videos

View our short videos to get an insight into how WearDetect works and how it delivers a high return on investment by minimising unplanned downtime.

Introduction to WearDetect

WearDetect provides maintenance warnings earlier than any other condition monitoring product.

(2 mins)

WearDetect explained

How the sensor works and how to get the best from the sensor in order to protect an asset from unexpected failure.

(5 mins)

WearDetect Starter Kit training

Training video to be used with the WearDetect Starter Kit, summarising how the sensor works, how to install it and how to get the best from the sensor to protect critical assets.

(6 mins)

WearDetect installation video (short)

WearDetect oil debris sensors can be installed directly out of the box using factory settings to be up and running within a few minutes.

The video covers unboxing and oil debris sensor installation.

(1.5 mins)

WearDetect installation & optimization video

For more specific sitations or where you have been using WearDetect for some time and wish to tailor the output, WearDetect can be fully optimized to suit your specific application.

The video covers unboxing, oil debris sensor set up, configuration, calibration and installation.

(6.5 mins)

Webinars

The webinars are available to download and watch on-demand.

WEBINAR: Discover machine wear earlier - a new approach to condition based monitoring

Continuous oil debris monitoring – why the world’s largest manufacturers have taken it on board.

This webinar provides information on continuous oil debris monitoring as an effective addition to a condition based monitoring (CBM) portfolio. This new approach to CBM allows earlier awareness of mechanical damage and maintenance needs, especially in scenarios such as variable load gearboxes and low speed systems where other techniques struggle to identify problems before it’s too late.

(45 mins)

WEBINAR: Predicting asset failures sooner in automotive manufacturing lines

Wear debris monitoring in machinery lubricants is becoming a key part of condition based monitoring (CBM) in automotive production environments.

This webinar provides information on how continuous oil debris monitoring is being used in automotive production to provide earlier awareness of equipment wear and maintenance needs especially in assets such as conveyor gearboxes and machine tool multi-spindle gearboxes, where other techniques struggle to identify problems in time for corrective action.

WearDetect Software

Overview

WearDetect oil debris sensors can be installed ‘out of the box’. However, to adjust the sensor parameters, please download the WearDetect software here. Please see the ‘WearDetect installation & optimization’ video in the VIDEOS tab.

Compatible Products
WearDetect oil debris sensors

Additional applications to support Gill products

Gill has a number of applications to support older products and older operating systems. For more information please contact support@gillsc.com specifying

Product name
Part number
Product serial number
PC operating system

Application notes

Pizza oven production lines

Heavy-duty gearboxes on the pizza ovens are critical to production. WearDetect was installed to provide essential real-time insight into the health of the oven gearboxes

Oil Debris Sensor prevents mechanical breakdown of speed reducer

Oil debris sensor detects early signs of component breakdown in speed reducer. Vibration monitoring techniques had proven insufficient to prevent downtime

Oil condition monitoring in wind turbines

Oil debris sensors are a powerful multi-point predictive maintenance tool providing the earliest warning of ferrous wear in wind turbine gearboxes

Gearbox reliability for extrusion machines

Oil debris sensors improve gearbox reliability on extrusion machines, providing operators with a clear picture of the health of the extruder

Maintenance professionals viewing manufacturing system data on a laptop

Ferrous debris sensor with Modbus integrates into existing manufacturing and distribution systems

High numbers of critical and highly loaded gearboxes in manufacturing plants or within conveyor drives in large scale distribution and warehousing facilities, benefit from ferrous debris sensors providing essential real-time insight into gearbox health. Outputs such as Modbus ensure these sensors can be readily integrated into existing systems.

Common causes of bearing failure in gearboxes

Gearbox failure can cause a complete machinery breakdown, expensive to repair as well as lost output. Common causes of bearing failure in gearboxes include…

LIQUID LEVEL SENSORS

WEAR DEBRIS SENSORS

POSITION SENSORS

ENGINE CONTROLS