The wear debris in hydraulic oil or lubricating oil has a wealth of equipment operating information, which is an important basis for large mechanical equipment detection and fault diagnosis. Based on traditional inductive oil detection technology, magnetic nanoparticles are exploited in this paper. A new inductive oil detection sensor is designed based on the characteristics of magnetic nanoparticles. The sensor improves detection sensitivity based on distinguishing between ferromagnetic and non-ferromagnetic wear debris. Magnetic nanoparticles increase the internal magnetic field strength of the solenoid coil and the stability of the internal magnetic field of the solenoid coil. During the experiment, the optimal position of the sensor microchannel was first determined, then the effect of the magnetic nanoparticles on the sensor's detection was confirmed, and finally the concentration ratio of the mixture was determined. The experimental results show that the inductive oil detection sensor made of magnetic nanoparticle material had a higher detection effect, and the signal-to-noise ratio (SNR) of 20-70 μm ferromagnetic particles was increased by 20%-25%. The detection signal-to-noise ratio (SNR) of 80-130 μm non-ferromagnetic particles was increased by 16%-20%. The application of magnetic nanoparticles is a new method in the field of oil detection, which is of great significance for fault diagnosis and the life prediction of hydraulic systems.

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Inductive Magnetic Nanoparticle Sensor based on Microfluidic Chip Oil Detection Technology.

High-sensitivity distinguishing and detection method for wear debris in oil of marine machinery

Inductive wear debris sensor has been proved to be an effective device for lubricant oil condition monitoring and fault diagnosis. However, the narrow internal diameter of current sensing coil, designed for high sensitivity, limits the oil throughput. To improve the throughput without sacrificing the sensitivity, a novel multichannel wear debris detection method based on time division multiplexing is presented in this work. Only one excitation signal is used to excite multiple sensing coils. Then, the signals from multiple sensing coils are combined with a serials of square waves separately, which are self-designed specially. As a result, the peak waveforms are lifted in different timeslots by the high-level voltages in squares waves. After that, the peaks of the signals are cut out and combined into one output signal. Then, we used synchronized sampling method to record the peak values of the output signal. The signals for all sensing channels are finally extracted from the recorded peak values. To validate the feasibility of the proposed method, we designed a ten-channel sensor system using time division multiplexing. Through the pseudo-dynamic and dynamic test, it is proved that the sensor could detect wear debris in different channels simultaneously and independently without sacrificing the sensitivity. In addition, the proposed method has the potential to integrate more channels into one system, which would contribute to high throughput real time lubricant oil detection.

A Novel Multichannel Inductive Wear Debris Sensor Based on Time Division Multiplexing

Metallic contaminants (solid) are generated by friction pair, causing wear of equipment by enters the lubricating system. This poses a great potential threat to the normal operation of such machines. The timely analysis and detection of debris can lead to the avoidance of mechanical failures. Abnormal wear in machinery may produce debris exceeding 10 μm. The traditional inductance detection method has low sensitivity and cannot meet the actual detection requirements. To boost the sensitivity of the inductance sensor, the mutual inductance of coils and the strong magnetic conductivity of permalloy was utilized to design a high sensitivity inductance sensor for the detection of debris in lubricating oil. This design was able to detect 10–15 μm iron particles and 65–70 μm copper particles in the oil. The experimental results illustrate that low-frequency excitation is the best for detecting ferromagnetic particles, while high-frequency excitation has the best effect for detecting non-ferromagnetic particles. This paper demonstrates the significant advantages of coil mutual inductance, and strong magnetic conductivity of permalloy in improving the detection sensitivity of oil debris sensors. This will provide technical support for wear detection in mechanical equipment and fault diagnosis.

https://www.mdpi.com/1424-8220/22/5/1833/pdf?version=1645792432

Research on High Sensitivity Oil Debris Detection Sensor Using High Magnetic Permeability Material and Coil Mutual Inductance

Wear debris detection is an effective method to determine the running state of the machine. Recently, the planar inductor is commonly used to detect wear debris. The previous studies have found that the inductive signal would be varied while changing the position of wear debris pass through. However, the effect of position on the wear debris detection is not well understood. In this paper, a novel detection system in which the position of wear debris pass through could be adjusted precisely is designed. By changing the position in horizontal or vertical direction, the inductive signals of the wear debris were acquired. In the horizontal direction, the experimental results show that the amplitude of the inductive signal first increases and then decreases when the position changes from the center of the planar inductor to the outer. The maximum inductive signal appears when the wear debris pass through the edge of the inner coil, which is 20% higher than that for the center and much higher than that for the edge of outer coil. In the vertical direction, the signal decreases almost linearly when the position is away from the planar inductor. For every 0.1 mm step far away the planar inductor, the signal amplitude drops by approximately 10%. The variation trend of our experimental results is consistent with the numerical simulation results of magnetic intensity around the planar inductor.

https://www.mdpi.com/1424-8220/19/22/4961/pdf

The Effects of Position on the Wear Debris Detection with Planar Inductor.

The inductive detection of wear debris in lubrication oil is an effective method to monitor the machine status. As the wear debris is usually micro scale, a micro inductive sensor is always used to detect them in research papers or high-tech products. However, the improvement of detection sensitivity for micro inductive sensors is still a great challenge, especially for early wear debris of 20 μm or smaller diameter. This paper proposes a novel method to improve the detection sensitivity of a micro inductive sensor. Regarding the magnetic powder surrounding the sensor, the magnetic field in the core of the sensor where the wear debris pass through would be enhanced due to the increased relative permeability. Thus, the inductive signal would be improved and the detection sensitivity would be increased. It is found that the inductive signal would linearly increase with increasing the concentration of the magnetic powder and this enhancement would also be effective for wear debris of different sizes. In addition, the detection limit of the micro inductive sensor used in our experiment could be extended to 11 μm wear debris by the proposed method.

https://www.mdpi.com/2072-666X/10/7/440/pdf

Chen Liang

Papers

Improving Sensitivity of a Micro Inductive Sensor for Wear Debris Detection with Magnetic Powder Surrounded

The Effects of Position on the Wear Debris Detection with Planar Inductor.