Portable Ferrograph Analyzer

Portable Ferrograph Analyzer – QualiFG™ Port

The Portable Ferrograph Analyzer QualiFG™ Port is a compact, field-ready ferrograph system engineered for rapid assessment of ferromagnetic wear debris in lubricating oil. It integrates electromagnetic particle capture with advanced image-recognition capabilities, enabling on-device wear particle imaging, classification of wear patterns, and generation of maintenance-oriented reports within a unified workflow.

Designed for reliability and condition monitoring teams, this portable solution supports fast screening directly at the asset location, eliminating the delay associated with full laboratory ferrography procedures. The system supports automated sample injection, automated cleaning cycles, trend monitoring, early-stage fault alerts, and report generation, all within a rugged portable enclosure suitable for onsite operation.

QualiFG™ Port is well-suited for field inspections, route-based oil analysis, and rapid condition evaluation tasks where immediate wear debris insights are critical. It helps maintenance teams identify developing issues earlier, supporting informed decisions before equipment degradation progresses into serious failure conditions.

Portable Ferrograph Analyzer – QualiFG™ Port Applications

Field screening for rotating equipment:
QualiFG™ Port is well-suited for rapid on-site evaluation of ferromagnetic wear debris in gearboxes, bearings, hydraulic units, and circulating oil systems. Its short analysis cycle allows maintenance teams to quickly determine whether equipment is operating normally or showing early signs of abnormal wear that require further inspection.

Trend monitoring and early warning:
This Ferrograph analyzer supports condition-based maintenance through historical data review, wear trend tracking, and particle concentration analysis. It enables operators to observe gradual changes in machine health, making it valuable for maintenance strategies focused on long-term performance patterns rather than single-point results.

Wear-type classification for maintenance decisions:
QualiFG™ Port categorizes ferromagnetic wear particles into key types, including abrasive wear particles, adhesive wear particles, sliding wear particles, and cutting wear particles. This classification enhances diagnostic clarity, helping maintenance teams interpret wear behavior more effectively and prioritize corrective actions.

Reporting and maintenance documentation:
The system is designed to support structured reporting needs across maintenance teams. It offers data review, export functions, wear condition evaluation, and maintenance guidance outputs, making it easier to maintain consistent inspection records across multiple sites and operational teams.

Standards

ASTM D7690 – Provides guidance for the microscopic characterization of wear and contaminant particles deposited on ferrograms. It is commonly referenced in ferrogram microscopy workflows for consistent particle evaluation and analysis practices.

ASTM D7684 – Establishes terminology and classification guidance for microscopic particle identification programs. It supports standardized description of wear particles, helping ensure consistent reporting and interpretation across oil analysis and condition monitoring systems.

Portable Ferrograph Analyzer – QualiFG™ Port Key Features

Portable field-ready design:
QualiFG™ Port features a compact, lightweight structure designed for onsite condition monitoring. Its form factor supports field-based screening, making it suitable for inspections outside traditional laboratory environments.

Electromagnetic adsorption and image recognition:
The system integrates electromagnetic particle capture with image-recognition technology to detect ferromagnetic wear debris in lubricating oil. This combined approach forms the core mechanism for particle detection and analysis.

High-definition optical imaging:
Equipped with 6× optical magnification and a 5 MP CMOS industrial camera (2592 × 1944 resolution), the system delivers detailed wear particle imaging. This level of clarity supports automated classification and structured reporting.

Reflective LED illumination:
An LED reflective lighting system enhances visibility of particle surface texture and coloration during imaging, improving consistency in wear particle evaluation.

Adjustable magnetic field control:
The magnetic field intensity can be adjusted across 256 levels, allowing flexible configuration for varying sample conditions and wear debris concentrations.

Automatic sample injection and cleaning:
The instrument includes automated sample injection and cleaning functions. Cleaning performance can be monitored through the software, with configurable sampling and cleaning durations for operational control.

Four wear-type outputs:
QualiFG™ Port categorizes wear particles into four groups: abrasive wear particles, adhesive wear particles, sliding wear particles, and cutting wear particles. This supports clearer interpretation of wear conditions beyond basic detection.

Automated reporting and trend analysis:
The software provides historical data review, trend analysis, wear particle statistics, and automated report generation with condition evaluation and maintenance guidance. This helps standardize documentation for condition monitoring programs.

Theory and Method

A Ferrograph screening system of this type operates by capturing ferromagnetic wear particles from a lubricating oil sample and analyzing them through optical imaging combined with software-based recognition. In QualiFG™ Port, electromagnetic adsorption draws ferromagnetic particles onto the inner surface of the detection cell, where they are arranged for optical inspection and digital analysis.

Once deposited, the particles are recorded by the optical imaging system, and the resulting images are processed using image-recognition techniques to assess particle size, shape, and wear characteristics. QualiFG™ Port applies a neural-network-based analysis approach to support real-time evaluation of particle morphology and dimensional features, enabling automated interpretation and structured reporting from the same dataset.

This approach is designed for rapid wear screening rather than full laboratory ferrogram microscopy. In practical use, it functions as an early-warning and trend-monitoring tool, helping maintenance teams identify abnormal wear patterns and determine when more detailed oil analysis or maintenance action is required.

Portable Ferrograph Analyzer – QualiFG™ Port Technical Specification

Parameter	QualiFG™ Port
Product Type	Portable Ferrograph Analyzer / Ferrograph
Detection Principle	Electromagnetic adsorption + image recognition
Detection Target	Ferromagnetic particles in lubricating oil
Detection Range	5–500 μm
Optical Magnification	6×
Camera	5 MP CMOS industrial camera
Camera Resolution	2592 × 1944
Light Source	LED reflective light source
Wear Type Output	Normal abrasive, adhesive wear, sliding wear, cutting wear
Output Indicators	Total wear amount, large/small particle counts, equivalent circle radius, major axis dimension, wear evaluation
Detection Duration	Less than 1 minute
Display	12.1-inch, 1280 × 800 color LCD touchscreen
CPU	8-core 64-bit processor; 4 Cortex-A76 + 4 Cortex-A55
GPU	ARM Mali-G610
NPU	Up to 6 TOPS
Memory	16 GB RAM
Storage	256 GB eMMC
Ports	USB / RJ45
Working Temperature	-20°C to 60°C
Power	DC 24 V or power adapter
Maximum Power	Less than 100 W
Materials	PP + aluminum alloy
Weight	10 ± 0.2 kg