Sensei Real-time Lubrication Intelligence System

Trico Corporation, a leading provider of lubrication management solutions, today introduced Sensei, a real-time lubrication intelligence system. Sensei wirelessly transmits oil level and ambient air temperature to a customizable, web-based dashboard. As a result, users gain real-time input on machine status and maintenance requirements. Sensei can:

• Reduce inspection time from hours to minutes per week.
• Reduce requirements for personnel to visit difficult- or dangerous-to-access areas.
• Help avoid downtime by providing alerts and warnings.
• Enable organizations to operate more efficiently by performing proactive, data-driven maintenance.

“The launch of Sensei represents a new ability to generate meaningful data faster and more efficiently than ever before. As a result, we are uniquely positioned to help customers develop cost-saving strategies and reduce the massive pressures of reliability,” says Jim Jung, president, Trico. “In combination with the services from the Trico Analysis Center, Sensei enables us to redefine lubrication management strategies for the Internet of Things era.”

The first wireless sensors available as part of the Sensei system are oil level sensors designed to accompany Trico’s line of 8-oz. Opto-Matic vented and closed constant level oilers. Pumps, motors, gearboxes, fans, blowers and other equipment use constant level oilers to maintain a consistent fluid level.

Industrial and manufacturing applications include those in machining, petrochemical, chemical processing, primary metals, pulp and paper, food and beverage, power generation, water management, mining and other industries. Maintenance managers, directors of operations, facility managers, lubrication technicians, millwrights and reliability engineers in these industries stand to gain valuable insights from Sensei’s real-time monitoring capability.

“Sensei has helped us rule out and identify problems,” says Mike Walton, ICML, MLT-II, mechanical technician at Irving Tissue, St. John, New Brunswick. Irving Tissue tested Sensei on the Yankee exhaust fans that assist in the drying process. Walton notes that the reliability team at first thought one fan had an oil leak because it lost so much oil in a short period, but historical data provided by Sensei showed that there were periods as long as 4 to 5 months where oil level stayed constant.

“On fan 200-190-21, Sensei enabled us to rule out a leak and look for other causes,” says Walton. “Conversely, fan 100-190-53 leaked constantly. On closer examination, we found it had a leaking fitting going to the bearing housing, as well as a bad seal. Work orders were entered to correct those problems.”

The Sensei system includes three components:

1. An oil sensor that measures the oil level, oil consumption and ambient temperature.
2. The Sensei gateway (a router) that securely receives data and transmits it to the cloud. The gateway handles up to 64 sensors at a radius of 250 feet. Repeaters expand the network as needed.
3. An intuitive, web-based dashboard for real-time intelligence (there is no need to install software). The dashboard is customizable with displays for oil level by device, daily alerts and several other functions.

“Due to competitive pressure, cost-saving requirements and retiring skilled trade talent, many companies no longer have in-house capabilities. That’s where Trico and our 100 years of lubrication expertise come in, helping customers turn data into action,” says Jung. “By pairing data from Sensei with our industry-leading oil lab services and analysis, Trico provides an unmatched ability to protect and extend the life of critical equipment.”

To create Sensei’s customized optical sensor pack that captures oil levels, Trico partnered with MarqMetrix, a Seattle-based company that also helped develop the wireless network solution that flows data into the Sensei cloud platform.

“Using patented technology, we can automate previously manual and labor intensive measurement processes. Sensei technology has limitless opportunities for industrial and manufacturing applications,” says Brian Marquardt, CEO of MarqMetrix.

To help ensure maximum impact with the expert monitoring made possible by Sensei, the system is only available through a select network of trained distribution partners, or directly through Trico. Companies can request access to a simulated Sensei dashboard that illustrates available information and configurability,.

Sensei oil level sensors are available as a complete oiler, but can be retrofit to existing Trico Opto-Matic installations by replacing the upper bulb assembly. It is not compatible with competitive oilers.