Engine Oil Quality Monitoring Using an Additively Manufactured X-Band Microwave Waveguide Sensor

Maintaining engine oil quality is critical for industrial machinery and transformers to ensure efficient operation and reduce the risk of failure. This paper presents a novel application of an X-band microwave sensor, using a third-order electroformed iris waveguide filter, for real-time, non-invasive engine oil quality monitoring. By detecting shifts in the dielectric properties of engine oil, the sensor accurately tracks oil degradation as it ages. Unlike traditional methods that require oil extraction and laboratory analysis, this sensor enables continuous, in-situ monitoring, providing immediate feedback without disrupting system operations. Any change in oil quality causes a frequency shift, as variations in its dielectric properties affect the waveguide’s resonance. This shift can be measured in real time, enabling accurate monitoring of oil degradation. Additional measurements were conducted using the coaxial probe technique to analyze the changes in the oil’s electrical behavior during various heating periods. Experimental results demonstrate the sensor’s sensitivity, with measurable frequency shifts of up to 10 MHz observed in the most aged oil samples. These shifts clearly correlate with the oil’s aging process, confirming the sensor’s potential for practical use in predictive maintenance. This system, utilizing an electroformed waveguide, offers a cost-effective and efficient solution for enhancing machinery longevity and optimizing maintenance schedules in industrial applications.