HORN Crank-Case Protection System

Diagnose Failures at Early Stage

The fundamental principle of the system revolves around measuring the thermos-voltage generated by a steel crankshaft as it glides along the metallic surface of its bearing shells.

The CPS signal serves as an early warning system, providing operators with crucial information regarding potential friction-related damages, particularly in the bearings. Through the display, operators are promptly informed about the condition, allowing for timely diagnosis of issues in the moving parts and preventing severe damage to the engine.

The system is also linked to the AMS system through pre-alarm and main-alarm relay outputs.

The CPS, along with its optional position encoder and pressure sensor, connects to the CPS Master unit, which calculates and monitors the measured values. Alarm level thresholds are established based on specific engine settings and parameters.

Directly connected to the AMS, the CPS Master Unit ensures a seamless integration.

Meanwhile, the CPS Slave Unit is responsible for displaying real-time data at the ECR, where measured values are showcased, and signal evaluation is carried out.

The CPS Sensor is installed on the housing, specifically on the free end of the crankshaft.

Application Test Carried Out

Multiple tests were performed on the CPS, some of them are explained below. The conclusion of the tests were:

• The mechanical system remains stable during continuous and prolonged operation. All rotating components are designed for extended maintenance-free use.
• The electronic system ensures fail-safe operation, eliminating interruptions caused by false alarms.
• Sufficient memory capacity for recording data from all input signals.

9 Cylinder Engine

Field assessment trial conducted on a power plant equipped with a 4-stroke diesel engine:

• Duration of the test conducted on an operational engine: approximately 1 year
• Evaluation of the measuring principle over an extended period in real-life conditions
• Mechanical tests performed on an operational engine
• Acquisition of data to assess the stability of mechanical and electronic systems
• Continuous long-term data recording to evaluate the stability of the system
• Enhancement of the oil sealing and alignment of rotating components within the crankcases.

16 Cylinder Engine

• Collection of data from various engines during engine wear/malfunction
• Gathering data on diverse oil temperature ranges
• Initial configuration of alarm levels for both pre and main alarms
• Testing was conducted using various foreign materials to simulate impurities in lubrication oil
• Examination of squeezed main bearings to mimic increased bearing temperature caused by wear or malfunction
• Comparison of alarm response time between the Oil Mist Detector and CPS
• Enhanced mechanical components to accommodate a larger crankshaft clearance.

12 Cylinder Engine

Field assessment trial conducted on the main generator engine of a cruise ship:

• Duration of the test conducted on an operational engine: approximately 1 year
• Testing conducted with enhanced mechanical components Improved electrical connections implemented to minimize application and system noise
• Continuous long-term data recording to assess alarm levels and system stability
• Optimization of alarm levels.

Field assessment trial conducted on the second main generator engine:

• Duration of the test: approximately 6 months
• Testing carried out to observe the impact of engine tolerance on the system
• Alternative electrical connections explored to reduce system costs without compromising accuracy
• Continuous long-term data recording to evaluate engine-specific alarm levels and system stability
• Optimization of alarm levels.