Virtual Fluid Lab Determines the Remaining Service Life of a Hydraulic Filter Element

Virtual Fluid Lab Determines the Remaining Service Life of a Hydraulic Filter Element

The VFL Concept

HYDAC developed a new smart concept, which combined with intelligent in-house sensors not only determines the remaining service life of filter elements, but even contributes to Predictive Maintenance of the machine.

Thanks to HYDAC decades of experience in the field of filtration and lube oils and based on our knowledge about the interactions between filtration, filter design and element development, we have developed an intelligent algorithm, which is directly integrated into the high-performing electronics of our smart sensors.

The remaining service life determination is specially attuned to HYDAC filter elements, which have been validated by comprehensive laboratory and field tests with regards to service life extension. Thanks to our patented Quality Protection interfaces, the use of original HYDAC elements is ensured.

With the aid of the VD … VFL (differential pressure measurement) or V1/4 … VFL (dynamic pressure measurement) sensors, the concept can be implemented regardless of the filter type and size.

The Virtual Fluid Lab is available with CAN Bus or with IO-Link communication systems.

How does VFL work?

The Virtual Fluid Lab VD ... VFL with IO-Link interface was specially developed to provide a solution that can determine the remaining service life of the filter element on the basis of pressure difference measurements. The sensor does this by using an internal algorithm to convert the filter’s pressure signal and the temperature of the fluid (which is read via IO-Link) into the current remaining service life of the filter element. This means that a signal is available that can be used for optimum planning of service work.

After the start-up phase, during which a constant remaining service life is output (9,999 h), the actual calculated remaining service life will be provided to the IO-Link master. This value decreases linearly as the operating hours of the filter element increase.

Why is determining the remaining service life of the filter element important?

  • Maximise use of element service life and therefore reduce your costs with a condition-based element change, full use of the filter element service life and maximised service intervals

  • Schedule your service in a proactive way with the continuous information about the remaining service life of the filter element and therefore highly improved machine availability

  • Identify "dirt conspicuous" machines within your fleet, before a total machine breakdown occurs and therefore avoid unscheduled machine downtimes

  • Basis for further functional development

(Example: Expanding the service life through the use of VFL)