The Intelligence Behind IntelliStick

The IntelliStick intrusion and oil condition monitoring system uses a patented sensor technology that electrically stimulates the oil at a particular low voltage and frequency that is designed to obtain the greatest response from both additives and oxidation by-products in the oil. The oil itself does not react electrically. The reading is obtained by measuring the overall conductivity of the oil and compensating for changes due to variations in the temperature of the oil.

The instrument continuously samples and monitors the oil while the vehicle or equipment is operating; scans for water, coolant or fuel intrusion; expresses oil condition over operating hours; identifies emulsion contamination with alarm; and reports fluid temperature with alarm.

Data and immediate alarms are output from the device by way of communications protocol options. 

Oil Condition / Conductance Graph

The oil condition takes time to change, so the graph will not change rapidly.

The Kauffman Conductance Curve is created by graphing the reading vs. engine run time. The different stages of oil life cause distinct changes in the curve. 

During the first stage the conductance reading is declining. This is because of the depletion of the lubricity, antioxidant and detergent package in the oil. All modern motor oils must contain these additives, without them the oil does not adequately protect the engine. A gradual decrease in conductance indicates that the additives are present and that they are being used up as they work. This is normal.

In the second stage the conductance will stay steady. This means that the lubricity additive package is almost entirely depleted and the oil lubricity is strongly dependent on the base oil. A small amount of polishing wear may be occurring on the engine. This second stage may have a gradual rise, because the antioxidant package is starting to lose its capability to stop basestock oxidation.

In the third stage the conductance is increasing. This is a result of the buildup of oxidation by-products. This means that the oil is oxidizing, breaking down and further losing its ability to lubricate. Engine polishing wear is accelerating. If this stage goes on for long enough the reading will start to level out again – this means that the viscosity of the oil is increasing and severity of engine wear is increasing.

Every Kauffman Curve will be unique based on the oil type, the brand, and the operating conditions of the engine.  Although each curve is unique, the characteristic turning points of the curve will be present with all oils because all oils degrade in the same way.  The difference between curves will be in the value and duration of each of the stages. For example, premium oils such as synthetic oils contain more additives and resist oxidation longer.

The IntelliStick software helps the user make sense of the data by doing a simple interpretation and presenting information about the state based on this. Read about this here : Using the Output 

Interpreting a given curve to determine an optimal oil change interval requires a certain amount of understanding of each of the stages, through which a compromise can be made between the oil efficiency and the life of the engine.

For example, if protecting the engine is the primary concern, the oil should be changed at the end of stage one just as the lubricity additives in the oil have been depleted.  On the other hand, if it is acceptable to incur some polishing wear, the oil change can be postponed until stage three is well underway.   

Contamination and Oil Loss

In addition to indicating the life stage of the oil, IntelliStick can also detect several types of oil contamination as well as major oil loss. 

A relatively sharp increase of the conductance reading indicates fuel contamination of the oil. This is because the fuel decreases the viscosity of the oil and tends to oxidize rapidly. Seeing a relatively sharp increase in conductance reading at an unexpected point on the curve may mean there is fuel leaking into the oil.

The IntelliStick sensor has two measurement arrays. Using the two of them together, harmful amounts of water and coolant can be detected. This is because the fine array has a particular spacing that makes it is extra sensitive to water or coolant droplets suspended in the oil. An increase in the ratio between the two array outputs signals the presence of water. When this occurs the red alarm light comes on and the software will display a message box alerting the user the next time the software is connected.

An oil loss is also detected by a comparing the two array outputs to determine that the sensor is only partially immersed. Likewise, when this occurs the alarm light comes on and the software will display a message box.