Visual imaging oil abrasive dust in-situ detection device and system

Abstract

The invention relates to the technical field of oil liquid monitoring, and discloses a visual imaging oil liquid abrasive dust in-situ detection device and a visual imaging oil liquid abrasive dust in-situ detection system. Wherein the light-transmitting tempered glass slide is attached to the wall of an inner cavity of the flow channel, the flow guide column is arranged in the inner cavity of the flow channel, an approximately-annular oil cavity is formed between the flow guide column and the light-transmitting tempered glass slide, and the flow guide column divides oil entering the flow channel to enable the oil to enter the oil cavity; the magnet is connected with the magnet exciting coil, is embedded into the runner and is attached to the outer surface of the light-transmitting tempered glass slide; electrifying the magnet exciting coil, and generating a magnetic field at an air gap between the N pole and the S pole of the magnet, so that the metal abrasive dust in the oil in the oil cavity is adsorbed at the air gap between the light-transmitting tempered glass slide and the magnet; light rays are radiated through the light source to illuminate abrasive dust, reflected light on the surface of the abrasive dust is imaged on the light sensing surface of the image device through the optical lens to form an abrasive dust image, in-situ detection of the oil abrasive dust is carried out through the abrasive dust image, and the detection efficiency of the oil abrasive dust is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of oil fluid monitoring, and particularly relates to an in-situ detection device and system for oil fluid wear debris with visual imaging. Background Art

[0002] With the continuous development and application of high-end equipment, it has become an urgent need to improve the technical level of equipment condition-based maintenance. The oil fluid wear debris monitoring technology is an important means for equipment fault diagnosis and maintenance. It can extract the wear debris characteristic parameter information from the in-use oil fluid of the equipment lubrication system, reflect the equipment wear failure problems caused by component aging or damage, realize the monitoring of the equipment operation state and fault warning, and thus reduce the equipment operation and maintenance costs.

[0003] Oil fluid wear debris sensors can be classified into non-image type and image visualization sensors according to the sensing method. Among them, non-image type wear debris sensors that detect various electrical parameters (such as resistance, electromagnetic induction, electrostatic induction, optoelectronic, and ultrasonic principles) have the characteristics of high sensitivity and fast detection speed. They can be used for on-line wear debris monitoring to obtain the mass concentration and material property characteristics of wear debris. However, they have poor anti-interference ability under harsh working conditions such as vibration and bubbles, resulting in low credibility of oil fluid wear debris detection, and they cannot detect the geometric information of wear debris in the oil fluid. The image visualization oil fluid wear debris sensing technology can obtain wear debris image information, and characterize wear by extracting the size, concentration, particle size, morphology, and color characteristic information of metal wear debris in the in-use lubricating oil fluid of the equipment, and can monitor the equipment operation state and diagnose wear faults in real time. In contrast, the image visualization oil fluid wear debris sensor can improve the anti-interference ability of oil fluid wear debris detection and the accuracy of equipment wear state monitoring and fault diagnosis, and has become the key to promoting the development of oil fluid wear debris on-line monitoring technology. However, it is difficult to miniaturize and apply the visualization oil fluid wear debris sensor on-line. In addition, the depth of field of the optical microscopic imaging component is limited and it is sensitive to the light transmittance of the oil fluid, making its research and design very difficult.

[0004] To solve the above technical problems, Patent CN200610041773.X discloses a small-volume on-line image-visible ferrographic probe, which can realize the orderly deposition of large and small wear debris in the acquisition area and can collect the image information of the wear debris deposition spectrum; Patents CN201310141313.4 and CN201610052551.1 propose a wear debris on-line monitoring probe based on video image acquisition, which extracts the visual feature information of metal particles in the oil by video monitoring, and realizes the on-line monitoring of mechanical wear state and the real-time judgment of oxidation wear state; Patent CN201410206588.6 discloses a full-field microscopic imaging oil wear debris detection device. Compared with Patent CN200610041773.X, the field of view of the wear debris image is increased, and the visual feature information of the wear debris can be extracted by bright-field imaging under reflected light, so as to improve the accuracy of the judgment of the on-line monitoring result of equipment wear. However, the image-visible oil wear debris detection devices involved in the above patents can only be used in the state of transparent oil. For low-transparency and opaque oils, it is impossible to effectively obtain the image information of the wear debris, and their oil chamber heights are all less than 1 mm, resulting in a small oil throughput and a low detection efficiency. Therefore, Patent CN201610976289.X and a journal paper (A panoramic ferrograph for on-site detection of oil wear debris) propose an oil wear debris detection device with dark-field imaging, which adsorbs the metal wear debris in the oil on the surface of the transparent window above the oil layer, avoiding the interference of the oil transmittance and bubbles on the acquisition of the wear debris image, so as to realize the acquisition and analysis of the visual information of the oil wear debris in the state of low transparency or even black oil. Patents CN202310470547.7, CN202110680718.X, CN201820860711.X and CN201820860695.4 use the full-field microscopic imaging oil wear debris detection device disclosed in Patent CN201410206588.6 to integrate and develop an on-line wear monitoring device. Patent CN201820861129.5 uses the on-line image-visible ferrographic reflection light imaging device disclosed in Patent CN201610976289.X to develop a reflection-type on-line visible ferrographic monitoring system, aiming to realize the on-line monitoring application of wear oil debris of industrial field equipment. However, there are congenital defects in the oil flow channel structure design of the devices proposed in Patent CN201610976289.X and CN201410206588.6, and their oil chamber cross-sectional area is about 5 mm 2 , resulting in an oil throughput of less than 5 ml / min. It is impractical to install it in the lubricating oil circuit of the equipment for on-line detection of oil wear debris. Therefore, the current oil wear debris monitoring devices still have the problem that the oil chamber is small, resulting in a small oil throughput, which is not conducive to the detection of oil wear debris. Summary of the Invention

[0005] The object of the present invention is to provide an in-situ detection device and system for visual imaging of oil debris, which can effectively improve the detection efficiency of oil debris.

[0006] To solve the above technical problems, an embodiment of the present invention provides an in-situ detection device for visual imaging of oil debris, including: A light-transmitting toughened glass sheet is fixedly mounted on the inner cavity wall of the flow channel. An oil inlet pipe joint and an oil outlet pipe joint are respectively installed at both ends of the flow channel. The bottom end of the diversion column is embedded in the oil outlet pipe joint and is placed in the inner cavity of the flow channel, so that an annular oil cavity is formed between the diversion column and the light-transmitting toughened glass sheet. After the oil fluid flows into the flow channel through the oil inlet pipe joint, the diversion column shunts the oil fluid, so that the oil fluid enters the inside of the oil cavity to generate an oil fluid circulation and flows out through the oil outlet pipe joint; The excitation module is composed of two rectangular iron cores, four cylindrical iron cores, four excitation coils and four pairs of magnets. The four cylindrical iron cores are clamped and fixed at the 4 right-angle ends between the two parallel rectangular iron cores. The four excitation coils are respectively wound around the four cylindrical iron cores. The four pairs of magnets are installed and fixed on the inner sides of the two parallel rectangular iron cores. By energizing each excitation coil, a pulsating magnetic field is generated at the air gap between the N pole and the S pole of each pair of magnets, and the metal debris in the oil fluid inside the oil cavity is adsorbed on the inner surface of the light-transmitting toughened glass sheet by the magnetic force of the pulsating magnetic field, and deposited debris is formed at the air gap between the N pole and the S pole of the magnet; The visual imaging module is placed in a rectangular space surrounded by two excitation coils and two rectangular iron cores and is perpendicular to the corresponding excitation coil. The visual imaging module is fixedly connected to the flow channel and includes an optical lens and an image device. By radiating light to the light-transmitting toughened glass sheet, the deposited debris formed on the inner surface of the light-transmitting toughened glass sheet is illuminated, and the radiated light is imaged on the photosensitive surface of the image device through the optical lens to form a deposited debris image, so as to perform in-situ detection of oil debris through the deposited debris image.

[0007] In some alternative embodiments, a planar transmission light source is provided on the surface of the diversion column, and a light guide reflection plate is also hermetically fixed. Among them, a wire through hole is machined inside the diversion column for arranging the energized wire of the planar transmission light source; The planar transmission light source is used to radiate light, and the light is projected onto the light-transmitting toughened glass sheet between the N pole and the S pole of the magnet through the light guide reflection plate to perform transmitted light illumination on the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass sheet.

[0008] In some alternative embodiments, the visual imaging module further includes a reflection light source, and the radiated light of the reflection light source is projected onto the light-transmitting toughened glass sheet between the N pole and the S pole of the magnet to perform reflected light illumination on the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass sheet.

[0009] In some alternative embodiments, if the optical magnification of the optical lens is 1.0× to 3.0× and the oil attenuation coefficient of the oil is less than 2.0, the reflected irradiance of the deposited debris image is less than the diffuse reflectance irradiance of the lower surface of the light guide reflector, and the contrast perspective ratio for characterizing the contrast of the deposited debris image under different oil attenuation coefficients is less than 0. Light is radiated through a planar transmission light source or a reflection light source to perform transmission light illumination or reflection light illumination on the deposited debris adsorbed on the inner surface of the transparent tempered glass sheet and located at the air gap between the N pole and the S pole of the magnet; If the optical magnification of the optical lens is 1.0× to 3.0× and the oil attenuation coefficient of the oil is greater than or equal to 2.0, the reflected irradiance of the deposited debris image is less than the diffuse reflectance irradiance of the lower surface of the light guide reflector, and the contrast perspective ratio is greater than or equal to 0. Light is radiated through a reflection light source to perform reflection light illumination on the deposited debris adsorbed on the inner surface of the transparent tempered glass sheet and located at the air gap between the N pole and the S pole of the magnet; Among them, the contrast perspective ratio is the ratio of the difference between the reflected irradiance and the diffuse reflectance irradiance to the total irradiance of the photosensitive surface of the image device, and the total irradiance is the sum of the reflected irradiance, the diffuse reflectance irradiance, and the backscattered irradiance of the photosensitive surface of the image device.

[0010] In some alternative embodiments, an adjusting screw sleeve is provided on the optical lens, and the optical magnification of the optical lens is adjusted by rotating the adjusting screw sleeve.

[0011] In some alternative embodiments, there are four visualization imaging modules. Each visualization imaging module is placed in a rectangular space surrounded by two adjacent excitation coils and two rectangular iron cores, and the angle between two adjacent visualization imaging modules is 90°.

[0012] In some alternative embodiments, the device further includes a mounting seat. A lens screw sleeve is provided on the visualization imaging module, and the visualization imaging module is embedded into the internal space of the mounting seat through the thread on the lens screw sleeve.

[0013] In some alternative embodiments, the height of the oil cavity is 0.5 mm to 5 mm.

[0014] In some alternative embodiments, the width of the air gap between the N pole and the S pole of the magnet is 0.5 mm to 5 mm.

[0015] An embodiment of the present invention further provides an in-situ detection system for oil debris with visualization imaging, including: A computer device with wireless communication function, a wireless network communicating through Ethernet / 4G / 5G, a wireless communication module, a micro control unit, a pump, a solenoid valve, and the above-mentioned in-situ detection device for oil debris with visualization imaging; The computer device sends a control instruction for indicating in-situ detection of oil debris. The control instruction is transmitted to the wireless communication module through a wireless network. The wireless communication module converts the control instruction into a signal and then sends it to the micro-control unit. The micro-control unit controls the pump and the solenoid valve to open, so that the oil flows into the flow channel through the oil inlet joint. After that, the flow guide column diverts the oil, enabling the oil to enter the oil cavity to generate an oil circulation. It controls each excitation coil to be energized, generating a pulsating magnetic field at the air gap between the N and S poles of each pair of magnets. The magnetic force of the pulsating magnetic field adsorbs the metal debris in the oil inside the oil cavity onto the inner surface of the light-transmitting toughened glass slide, forming deposited debris at the air gap between the two magnetic poles of the magnet. It controls the reflection light source of the visualization imaging module to illuminate the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass slide, so that the reflected light on the surface of the deposited debris is imaged on the photosensitive surface of the image device through the optical lens, forming an image of the deposited debris. The visualization imaging module is also used to transmit the obtained image of the deposited debris to the computer device through the wireless communication module and the wireless network. The computer device processes and analyzes the image of the deposited debris to complete the in-situ detection of oil debris.

[0016] The in-situ detection device for oil debris with visualization imaging provided by the present invention has the following beneficial effects: Due to the limited depth of field of the existing image visualization oil debris sensor microscopic imaging system, in order to obtain a clear image of the debris, the height of the oil cavity in the flow channel of the image visualization debris sensor is mostly between 50 and 1000 μm. The narrow oil cavity and low oil flow rate will limit the oil throughput of the image visualization debris sensor and affect the online monitoring efficiency of oil debris. In the present invention, by mounting a light-transmitting toughened glass slide on the inner cavity wall of the flow channel and arranging a flow guide column in the inner cavity of the flow channel, an approximately annular oil cavity is formed between the flow guide column and the light-transmitting toughened glass slide. When the oil flows into the flow channel, the flow guide column diverts the oil, enabling the oil to flow along the approximately annular oil cavity close to the edge of the flow channel. Compared with the traditional oil cavity, it can improve the oil throughput of the flow channel of the image visualization oil debris sensor without affecting the microscopic imaging effect of the oil debris, thereby effectively improving the detection efficiency of the oil debris. Description of the Drawings

[0017] One or more embodiments are exemplarily illustrated by the pictures in the corresponding drawings. These exemplary illustrations do not constitute a limitation on the embodiments.

[0018] Figure 1 is a schematic structural diagram of an in-situ detection device for oil debris with visualization imaging according to an embodiment of the present invention; Figure 2 is a schematic structural diagram of an excitation module according to an embodiment of the present invention; Figure 3It is a schematic structural diagram of a visualization imaging module provided according to an embodiment of the present invention; Figure 4 It is a decoupled strand schematic diagram of a flow guiding column provided according to an embodiment of the present invention; Figure 5 It is a flowchart of a visualization imaging method for oil fluid debris detection provided according to an embodiment of the present invention; Figure 6 (a) It is a deposited debris spectrogram of reflected light and transmitted light of gearbox oil provided according to an embodiment of the present invention; Figure 6 (b) It is a deposited debris spectrogram of reflected light and transmitted light of gasoline engine oil provided according to an embodiment of the present invention; Figure 6 (c) It is a deposited debris spectrogram of reflected light and transmitted light of diesel engine oil provided according to an embodiment of the present invention; Figure 7 It is a schematic structural diagram of a visualization imaging in-situ detection system for oil fluid debris provided according to an embodiment of the present invention; Among them, flow channel 1; flow guiding column 2; excitation module 3; visualization imaging module 4; light-transmitting toughened glass sheet 5; oil cavity 6; mounting seat 7; inlet pipe joint 8; outlet pipe joint 9; computer 10; wireless network 11; wireless communication module 12; micro control unit 13; pump 14; solenoid valve 15; planar transmission light source 21; light guiding and reflecting plate 22; wire through hole 23; rectangular iron core 31; cylindrical iron core 32; excitation coil 33; magnet 34; optical lens 41; image device 42; reflected light source 43; adjusting screw sleeve 44; lens screw sleeve 45. Detailed implementation manners

[0019] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the embodiments of the present invention will be elaborated in detail below with reference to the accompanying drawings. However, those of ordinary skill in the art can understand that in the embodiments of the present invention, many technical details are proposed for the convenience of readers to better understand the present invention. However, even without these technical details and various changes and modifications based on the following embodiments, the technical solutions required to be protected by the present invention can still be achieved. The following division of each embodiment is for the convenience of description and should not constitute any limitation to the specific implementation manner of the present invention. Each embodiment can be combined and cross-referenced with each other on the premise of no contradiction.

[0020] An embodiment of the present invention relates to a visualization imaging in-situ detection device for oil fluid debris. The implementation details of the visualization imaging in-situ detection device for oil fluid debris in this embodiment will be specifically described below. The following content is only the implementation details provided for the convenience of understanding and is not necessary for implementing this solution.

[0021] The specific structure of the in-situ detection device for visual imaging of oil wear debris in this embodiment is as follows Figure 1 shown, which includes a flow channel 1, a diversion column 2, an excitation module 3, and a visual imaging module 4.

[0022] Among them, a light-transmitting toughened glass sheet 5 is fixedly mounted on the inner cavity wall of the flow channel 1. An oil inlet pipe joint 8 and an oil outlet pipe joint 9 are respectively installed at both ends of the flow channel 1. The bottom end of the diversion column 2 is embedded in the oil outlet pipe joint 9 and is placed in the inner cavity of the flow channel 1, so that an approximately annular oil cavity 6 is formed between the diversion column 2 and the light-transmitting toughened glass sheet 5, and the height of the oil cavity 6 can be 0.5 mm to 5 mm. Therefore, after the oil fluid specifically flows into the flow channel 1 through the oil inlet pipe joint 8 of the flow channel 1, the oil fluid can be shunted by the diversion column 2, so that the oil fluid enters the interior of the oil cavity 6 to generate an oil fluid circulation, and flows out of the flow channel 1 through the oil outlets on both sides of the oil outlet pipe joint 9 of the flow channel 1.

[0023] The specific structure of the excitation module 3 is as follows Figure 2 shown, which is composed of two rectangular iron cores 31, four cylindrical iron cores 32, four excitation coils 33, and four pairs of magnets 34. The four cylindrical iron cores 32 are clamped and fixed at the 4 right-angle ends between the two parallel rectangular iron cores 31. The four excitation coils 33 are respectively wound around the four cylindrical iron cores 32. The four pairs of magnets 34 are installed and fixed on the inner sides of the two parallel rectangular iron cores 31, and the two can be closely attached to reduce magnetic leakage. The magnet 34 includes two magnetic poles (i.e., the N pole and the S pole), and there is a certain distance air gap between the N pole and the S pole, and the air gap width can be 0.5 mm to 5 mm. Therefore, by energizing each excitation coil 33, a high-gradient pulsating magnetic field can be generated at the air gap between the N pole and the S pole of each pair of magnets 34. The magnetic force of the high-gradient pulsating magnetic field can adsorb the metal wear debris in the oil fluid inside the oil cavity 6 on the inner surface of the light-transmitting toughened glass sheet 5 to form deposited wear debris at the air gap between the N pole and the S pole of the magnet 34.

[0024] The specific structure of the visual imaging module 4 is as follows Figure 3 shown, which is placed in the rectangular space surrounded by two excitation coils 33 and two rectangular iron cores 31 and is perpendicular to the corresponding excitation coil 33. The visual imaging module 4 is fixedly connected to the flow channel 1 and includes an optical lens 41 and an image device 42. Therefore, by irradiating light on the light-transmitting toughened glass sheet 5, the deposited wear debris formed on the inner surface of the light-transmitting toughened glass sheet 5 is illuminated, so that the irradiated light is imaged on the photosensitive surface of the image device 42 through the optical lens 41 to form a deposited wear debris image, so as to perform in-situ detection of oil wear debris through image processing and analysis of the deposited wear debris.

[0025] In this embodiment, due to the limited depth of field of the existing microscopic imaging system of the image visualization oil debris sensor, in order to obtain clear debris images, the height of the oil chamber in the flow channel of the image visualization debris sensor is mostly between 50 and 1000 μm. The narrow oil chamber and low oil flow velocity will limit the oil throughput of the image visualization debris sensor and affect the online monitoring efficiency of oil debris. In this embodiment, a light-transmitting tempered glass sheet is mounted on the inner cavity wall of the flow channel, and a flow guiding column is arranged in the inner cavity of the flow channel, so that an approximately annular oil chamber is formed between the flow guiding column and the light-transmitting tempered glass sheet. When the oil flows into the flow channel, the flow guiding column is used to divide the oil flow, so that the oil flows close to the approximately annular oil chamber at the edge of the flow channel. Compared with the traditional oil chamber, the oil throughput of the flow channel of the image visualization oil debris sensor is increased without affecting the microscopic imaging effect of oil debris.

[0026] In some embodiments, there is at least one and at most four visualization imaging modules 4. Each visualization imaging module 4 is placed in a rectangular space surrounded by two adjacent excitation coils 33 and two rectangular iron cores 31, and the angle between two adjacent visualization imaging modules 4 is 90°. Since the visualization imaging module 4 is the module for obtaining the deposited debris image in the present invention, by setting a plurality of visualization imaging modules 4, the monitoring efficiency of metal debris in oil can be effectively improved.

[0027] In one example, the in-situ detection device for oil debris with visualization imaging of this embodiment further includes a mounting seat 7. A lens screw sleeve 45 is provided on the visualization imaging module 4, and the visualization imaging module 4 is embedded into the internal space of the mounting seat 7 through the thread on the lens screw sleeve 45.

[0028] In some embodiments, the specific structure of the flow guiding column 2 of the present invention is as Figure 4 shown. A planar transmission light source 21 is arranged on the surface of the flow guiding column 2, and a light guiding reflector 22 is also hermetically fixed; wherein, a wire through hole 23 is machined inside the flow guiding column 2 for arranging the energized wire of the planar transmission light source 21. Therefore, in this embodiment, the above-mentioned light radiating to the light-transmitting tempered glass sheet 5 can be generated by the planar transmission light source 21. At this time, the light radiated by the planar transmission light source 21 is projected onto the light-transmitting tempered glass sheet 5 between the N pole and S pole of the magnet 34 through the light guiding reflector 22, and transmitted light illumination is performed on the deposited debris adsorbed on the inner surface of the light-transmitting tempered glass sheet 5 to form a deposited debris image.

[0029] In some other embodiments, the visualization imaging module 4 further includes a reflection light source 43. Therefore, in this embodiment, the above-mentioned light rays radiated to the light-transmitting tempered glass sheet 5 can be generated by the reflection light source 43. At this time, the light rays radiated by the reflection light source 43 are projected onto the light-transmitting tempered glass sheet 5 between the N pole and the S pole of the magnet 34, and the deposited abrasive particles adsorbed on the inner surface of the light-transmitting tempered glass sheet 5 are illuminated by reflected light. And in this case, after the radiated light rays of the reflection light source 43 are reflected by the light guide reflection plate 22 and enter the optical lens 41, a background of the deposited abrasive particle image is formed on the photosensitive surface of the image device 42.

[0030] In a specific implementation, if the optical magnification of the optical lens 41 is 1.0× to 3.0×, and the oil attenuation coefficient of the oil is less than 2.0, then the reflected irradiance of the deposited abrasive particle image is less than the diffuse reflectance irradiance on the lower surface of the light guide reflection plate 22, and the contrast perspective ratio for characterizing the contrast of the deposited abrasive particle image under different oil attenuation coefficients is less than 0. The light rays are radiated by the plane transmission light source 21 or the reflection light source 43 to perform transmitted light illumination or reflected light illumination on the deposited abrasive particles adsorbed on the inner surface of the light-transmitting tempered glass sheet 5 and located at the air gap between the N pole and the S pole of the magnet 34. If the optical magnification of the optical lens 41 is 1.0× to 3.0× (for example, 2.2×), and the oil attenuation coefficient of the oil is greater than or equal to 2.0, then the reflected irradiance of the deposited abrasive particle image is less than the diffuse reflectance irradiance on the lower surface of the light guide reflection plate 22, and the contrast perspective ratio is greater than or equal to 0. The light rays are radiated by the reflection light source 43 to perform reflected light illumination on the deposited abrasive particles adsorbed on the inner surface of the light-transmitting tempered glass sheet 5 and located at the air gap between the N pole and the S pole of the magnet 34. Among them, the contrast perspective ratio is the ratio of the difference between the reflected irradiance and the diffuse reflectance irradiance to the total irradiance of the photosensitive surface of the image device 42, and the total irradiance is the sum of the reflected irradiance, the diffuse reflectance irradiance, and the backscattered irradiance of the photosensitive surface of the image device 42.

[0031] An adjusting screw sleeve 44 is provided on the optical lens 41, and the optical magnification of the optical lens 41 is adjusted by rotating the adjusting screw sleeve 44.

[0032] It can be seen that the present invention provides two schemes for radiating light rays to the light-transmitting tempered glass sheet 5, and according to the optical magnification of the used optical lens 41, two schemes for forming the deposited abrasive particle image are provided.

[0033] Based on this, the present invention also provides two schemes for forming a sediment wear debris image (i.e., a visualization imaging method for large-throughput oil fluid wear debris detection) to achieve online acquisition of the sediment wear debris image, so as to verify the above two schemes for forming a sediment wear debris image through the visualization imaging method of this embodiment. That is, the present invention determines which visualization imaging method for large-throughput oil fluid wear debris detection to specifically adopt when using oils with different oil attenuation coefficients on the premise that the optical magnification of the optical lens 41 of the visualization imaging module 4 is 2.2× through a large-throughput visualization imaging in-situ detection method for oil fluid wear debris.

[0034] The principle it adopts is as follows: Calculate the reflected irradiance on the surface of the sediment wear debris map received by the photosensitive surface of the image device 42 in the visualization imaging module 4, the diffuse reflected irradiance on the lower surface of the light guide reflection plate 22, and the backscattered irradiance of the oil fluid in the oil cavity 6, that is, the backscattered irradiance of the photosensitive surface of the image device 42. Then use the contrast perspective ratio to quantitatively describe the contrast of the wear debris image in visualization imaging under different oil attenuation coefficients, establish a reflection light imaging contrast perspective ratio model based on the linear superposition of irradiance, and finally, under the condition of an optical magnification of 2.2×, simulate and calculate the numerical relationship between the oil attenuation coefficient and the contrast perspective ratio, and determine the visualization imaging method for oil fluid wear debris detection according to the change ranges of the oil attenuation coefficient and the contrast perspective ratio. The specific implementation steps are as Figure 5 shown, including: S1: Assume that the sediment wear debris is closely attached to the light-transmitting toughened glass sheet 5, and regard the surface of the sediment wear debris under reflected light as a Lambert cosine body with the same reflectivity, so as to deduce the reflected irradiance x’, y’ of the sediment wear debris at the coordinate point of the photosensitive surface of the image device 42 ( ) as: ; In the formula, θ 1 is the angle between the radiation light on the surface of the sediment wear debris and the normal line, ω 1 is the angle between the refraction angle of the light after entering the air and the principal optical axis, D 0 is the object-side entrance pupil diameter of the optical lens 41, τ 0 is the light transmittance of the optical lens 41, ρ n is the reflectivity of the sediment wear debris, R T is the reflectivity of the light-transmitting toughened glass sheet 5, that is, , and are the refractive indices of the light-transmitting toughened glass sheet 5 and air respectively, f is the effective focal length of the optical lens 41, βis the optical magnification of the optical lens 41, and I0 is the luminous intensity in the direction of the principal optical axis of the optical lens 41. H is the distance between the reflection light source 43 and the deposition interface of the deposited abrasive debris. is the effective radius of the annular reflection light source 43.

[0035] S2: Divide the lower surface of the light guide reflection plate 22 into several micro-elements, and each micro-element is regarded as a Lambertian cosine body with uniform irradiance. After the oil chamber is filled with oil, any Lambertian cosine body micro-element dS 's radiation rays will pass through the light guide reflection plate 22, the oil layer, and the light-transmitting toughened glass sheet 5 and enter the entrance pupil of the optical lens 41. Assume that the entrance pupil of the optical lens 41 coincides with the object-side principal plane. Use the image-plane coordinates and the optical magnification to characterize the micro-element coordinates on the lower surface of the light guide reflection plate 22. The micro-element dS forms a micro-element image on the photosensitive surface of the image device 42 through the optical lens 41 dS’ , and it can be deduced that the diffuse reflection irradiance of the light guide reflection plate 22 at the coordinate point ([[]] x’ , y’ ) on the photosensitive surface of the image device 42 is: ; In the formula, θ 2 is the exit angle of the radiation rays of the micro-element dS . After refraction at the quartz window-air interface, ω 3 is the angle between the radiation rays to the center of the entrance pupil of the optical lens 41 and the principal optical axis, c 1 is the height of the oil chamber 6 between the light-transmitting toughened glass sheet 5 and the light guide reflection plate 22, c 2 and c 3 are the thicknesses of the light-transmitting toughened glass sheet 5 and the light guide reflection plate 22 respectively, ρ b is the optical reflection coefficient of the surface of the light guide reflection plate 223, α is the incident angle of the radiation rays of the reflection light source 43, and γ is the refraction angle of the radiation rays from the air into the upper light-transmitting toughened glass sheet 5. The refractive indices of the light-transmitting toughened glass sheet 5, the light guide reflection plate 22, and the oil are similar, and the difference is ignored. Then there is γ is always equal to arcsin(n air sinα / n gls )，C 0 is the oil attenuation coefficient, E 0([[]] x’, y’ ) is the irradiance distribution of the reflection light source 43 received on the surface of the light guide reflection plate 22.

[0036] S3: Divide the oil layer with a thickness of c 1 in the oil chamber 6 into rectangular micro-elements with equal thickness. All the micro-elements are parallel to the photosensitive surface of the image device 42. Considering the light energy loss absorbed by the oil layer from the radiation light of the reflection light source 43, the backscattering irradiance received by the photosensitive surface of the image device 42 can be deduced as follows: ; S4: The total irradiance received by the photosensitive surface of the image device 42 can be regarded as the linear superposition of the reflection irradiance of the deposited wear debris, the diffuse reflection irradiance of the light guide reflection plate 22, and the backscattering irradiance of the oil fluid. The contrast perspective ratio C R ( x’, y’ ) is described as the ratio of to the total irradiance . Then we have:

[0037] (1) Under the condition that the optical magnification β = 2.2× and C 0 < 2.0, through simulation calculation, we can obtain , and the contrast perspective ratio C R ( x’, y’ ) < 0. At this time, the in-situ detection device for oil fluid wear debris with large-flux visualization imaging can use the reflection light source 43 and the plane transmission light source 21 to conduct on-line monitoring of oil fluid wear debris, and can detect the deposited wear debris images of transmitted light and reflected light; (2) Under the condition that the optical magnification β = 2.2× and C 0 ≥ 2.0, through simulation calculation, we can obtain , and the contrast perspective ratio C R ( x’, y’ ) ≥ 0. At this time, the in-situ detection device for oil fluid wear debris with large-flux visualization imaging can use the reflection light source 43 to conduct on-line monitoring of oil fluid wear debris, and can detect the deposited wear debris images of reflected light.

[0038] In one example, the in-situ detection device for oil fluid wear debris with visualization imaging of the present invention carried out an on-line acquisition experiment of oil fluid wear debris images, and detected the metal wear debris in gearbox oil, gasoline engine oil, and diesel engine oil with oil fluid attenuation coefficients of approximately 1.15, 2.28, and 3.86 respectively. For the experimental results, please refer to Figure 6 .

[0039] When the oil attenuation coefficient is 1.15(1±0.3%), since the diffuse reflection light can penetrate through the oil layer, a bright background is formed on the photosensitive surface of the image device 42, realizing bright-field imaging of wear debris. In the reflected light wear debris spectrogram, the black wear debris image is clearly distinguishable, and some wear debris produces reflection. In the transmitted spectrum, the wear debris with projection imaging has a high recognition rate, as shown in Figure 6 (a) in; when the oil attenuation coefficient is 2.28(1±0.3%), since a large amount of the diffuse reflection light is absorbed and consumed in the oil layer, the contrast perspective ratio of the photosensitive surface of the image device 42 decreases, resulting in a reduced contrast between the background and the wear debris image in the reflected light wear debris spectrogram, increasing the difficulty of identifying the wear debris image. Moreover, the contrast between the background and the wear debris image in the transmitted spectrum decreases sharply, and the wear debris image cannot be effectively identified, as shown in Figure 6 (b) in; when the oil attenuation coefficient is 3.86(1±0.3%), a large amount of the energy of the diffuse reflection light and the backscattered light is absorbed, resulting in an enhanced image contrast between the wear debris and the black background. In the reflected light wear debris spectrogram, large wear debris and wear debris chains have a high recognition rate, realizing dark-field imaging of wear debris. However, due to the extremely low light transmittance of the oil, the intensity of the transmitted light received by the photosensitive surface of the image device 42 is less than its photosensitive sensitivity, and the image contrast between the wear debris and the background in the transmitted light wear debris spectrogram is zero. At this time, the detection of wear debris by transmitted light fails, as shown in Figure 6 (c) in.

[0040] In summary, through the online acquisition experiment of the reflected light and transmitted light wear debris images, the visualization imaging method and detection performance of the in-situ detection device for oil wear debris with visualization imaging of the present invention were tested. The experimental results show that when the oil attenuation coefficient is less than 2.0, the present invention can effectively obtain the visual information of wear debris with bright-field imaging from the light-transmitting oil. The larger the oil attenuation coefficient, the more blurred the wear debris image in the reflected light wear debris spectrogram; when the oil attenuation coefficient is greater than 2.0, the present invention can effectively obtain the visual information of wear debris with dark-field imaging from low-light-transmitting and non-light-transmitting oils. The larger the oil attenuation coefficient, the clearer the wear debris image in the reflected light wear debris spectrogram, and the best wear debris imaging quality can be obtained in the central field of view area of the spectrogram. The present invention has engineering significance and application value for detecting metal wear debris in oil by using the optical imaging principle and realizing intelligent monitoring of the mechanical transmission system of major equipment.

[0041] An embodiment of the present invention relates to an in-situ detection system for oil wear debris with visualization imaging. The implementation details of the in-situ detection system for oil wear debris with visualization imaging in this embodiment will be specifically described below. The following content is only the implementation details provided for convenient understanding and is not necessary for implementing this solution.

[0042] The specific structure of the in-situ detection system for oil wear debris with visualization imaging in this embodiment is as shown in Figure 7As shown in the figure, it includes: a computer device 10 with wireless communication function, a wireless network 11 communicating via Ethernet / 4G / 5G, a wireless communication module 12, a micro-control unit 13, a pump 14, a solenoid valve 15, and an in-situ detection device for visual imaging of oil debris as described in any of the above embodiments.

[0043] The working principle of the in-situ detection system for visual imaging of oil debris in this embodiment is as follows: The computer device 10 sends a control instruction for indicating in-situ detection of oil debris. The control instruction is transmitted to the wireless communication module 12 through the wireless network 11. The wireless communication module 12 converts the control instruction into a signal and then sends it to the micro-control unit 13; The micro-control unit 13 controls the pump 14 and the solenoid valve 15 to open, so that the oil flows into the flow channel 1 through the oil inlet joint 8. After that, the flow guide column 2 shunts the oil, enabling the oil to enter the inside of the oil cavity 6 to generate an oil circulation; controls each excitation coil 33 to be energized, so that a pulsating magnetic field is generated at the air gap between the N pole and the S pole of each pair of magnets 34, and the magnetic force of the pulsating magnetic field adsorbs the metal debris in the oil inside the oil cavity 6 on the inner surface of the light-transmitting toughened glass sheet 5, forming deposited debris at the air gap between the two magnetic poles of the magnet 34; controls the reflection light source 43 of the visual imaging module 4 to illuminate the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass sheet 5, so that the reflected light on the surface of the deposited debris is imaged on the photosensitive surface of the image device 42 through the optical lens 41, forming an image of the deposited debris; The visual imaging module 4 is also used to transmit the obtained image of the deposited debris to the computer device 10 through the wireless communication module 12 and the wireless network 11. The computer device 10 processes and analyzes the image of the deposited debris to complete the in-situ detection of oil debris.

[0044] In this embodiment, the computer with wireless communication function communicates directly with the wireless communication module for wireless data transmission, and can realize on-line detection of oil debris from mechanical equipment wear within the scope of the industrial field local area network. Compared with the traditional technology, the present invention can not only realize on-line detection of oil debris in the form of visual imaging, but also improve its detection ability by more than 4 times.

[0045] Those of ordinary skill in the art can understand that the above embodiments are specific embodiments for implementing the present invention. In actual applications, various changes can be made in form and details without departing from the spirit and scope of the embodiments of the present invention. Any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the embodiments of the present invention. Therefore, the protection scope of the embodiments of the present invention should be subject to the scope defined by the claims.

Claims

1. An in-situ detection device for oil debris by visual imaging, characterized in that, Including: A flow channel (1), a flow guiding column (2), an excitation module (3), and a visualization imaging module (4); A light-transmitting toughened glass sheet (5) is fixedly mounted on the inner cavity wall of the flow channel (1). An oil inlet pipe joint (8) and an oil outlet pipe joint (9) are respectively installed at both ends of the flow channel (1). The bottom end of the flow guiding column (2) is embedded in the oil outlet pipe joint (9) and is arranged in the inner cavity of the flow channel (1), so that an annular oil cavity (6) is formed between the flow guiding column (2) and the light-transmitting toughened glass sheet (5). After the oil flows into the flow channel (1) through the oil inlet pipe joint (8), the flow guiding column (2) diverts the oil, enabling the oil to enter the interior of the oil cavity (6) to generate an oil circulation and flow out through the oil outlet pipe joint (9); The excitation module (3) is composed of two rectangular iron cores (31), four cylindrical iron cores (32), four excitation coils (33), and four pairs of magnets (34). The four cylindrical iron cores (32) are clamped and fixed at the 4 right-angle ends between two mutually parallel rectangular iron cores (31). The four excitation coils (33) are respectively wound around the four cylindrical iron cores (32). The four pairs of magnets (34) are fixedly installed on the inner sides of the two mutually parallel rectangular iron cores (31). By energizing each excitation coil (33), a pulsating magnetic field is generated at the air gap between the N pole and the S pole of each pair of magnets (34), and the magnetic force of the pulsating magnetic field adsorbs the metal debris in the oil inside the oil cavity (6) onto the inner surface of the light-transmitting toughened glass sheet (5), so as to form deposited debris at the air gap between the N pole and the S pole of the magnet (34); The visualization imaging module (4) is placed in a rectangular space surrounded by two excitation coils (33) and two rectangular iron cores (31) and is perpendicular to the corresponding excitation coil (33). The visualization imaging module (4) is fixedly connected to the flow channel (1) and includes an optical lens (41) and an image device (42). By irradiating light on the light-transmitting toughened glass sheet (5), the deposited debris formed on the inner surface of the light-transmitting toughened glass sheet (5) is illuminated, and the irradiated light is imaged on the photosensitive surface of the image device (42) through the optical lens (41) to form a deposited debris image, so as to perform in-situ detection of oil debris through the deposited debris image.

2. The in-situ detection device for oil debris by visual imaging according to claim 1, characterized in that A planar transmission light source (21) is arranged on the surface of the flow guiding column (2), and a light guide reflection plate (22) is also hermetically fixed. Among them, a wire through-hole (23) is machined inside the flow guiding column (2) for arranging the energizing wire of the planar transmission light source (21); The planar transmission light source (21) is used for irradiating light. The light is projected onto the light-transmitting toughened glass sheet (5) between the N pole and the S pole of the magnet (34) through the light guide reflection plate (22) to perform transmitted light illumination on the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass sheet (5).

3. The in-situ detection device for oil debris by visual imaging according to claim 2, wherein, The visualization imaging module (4) further includes a reflection light source (43). The radiation light of the reflection light source (43) is projected onto the light-transmitting toughened glass sheet (5) between the N pole and the S pole of the magnet (34) to perform reflected light illumination on the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass sheet (5).

4. The in-situ detection device for oil debris in visual imaging according to claim 3, characterized in that If the optical magnification of the optical lens (41) is 1.0× to 3.0× and the oil attenuation coefficient of the oil fluid is less than 2.0, the reflected irradiance of the deposited wear debris image is less than the diffuse reflectance irradiance of the lower surface of the light guide reflector (22), and the contrast perspective ratio for characterizing the contrast of the deposited wear debris image under different oil attenuation coefficients is less than 0. Light is radiated through the planar transmission light source (21) or the reflection light source (43) to perform transmission light illumination or reflection light illumination on the deposited wear debris adsorbed on the inner surface of the light-transmitting tempered glass slide (5) and located at the air gap between the N pole and the S pole of the magnet (34). If the optical magnification of the optical lens (41) is 1.0× to 3.0× and the oil attenuation coefficient of the oil fluid is greater than or equal to 2.0, the reflected irradiance of the deposited wear debris image is less than the diffuse reflectance irradiance of the lower surface of the light guide reflector (22), and the contrast perspective ratio is greater than or equal to 0. Light is radiated through the reflection light source (43) to perform reflection light illumination on the deposited wear debris adsorbed on the inner surface of the light-transmitting tempered glass slide (5) and located at the air gap between the N pole and the S pole of the magnet (34). Among them, the contrast perspective ratio is the ratio of the difference between the reflected irradiance and the diffuse reflectance irradiance to the total irradiance of the photosensitive surface of the image device (42), and the total irradiance is the sum of the reflected irradiance, the diffuse reflectance irradiance, and the backscattering irradiance of the photosensitive surface of the image device (42).

5. The in-situ detection device for oil debris in visual imaging according to claim 4, characterized in that An adjusting screw sleeve (44) is provided on the optical lens (41), and the optical magnification of the optical lens (41) is adjusted by rotating the adjusting screw sleeve (44).

6. The in-situ detection device for visual imaging of oil debris according to any one of claims 1 to 5, characterized in that There are four visualization imaging modules (4), and each visualization imaging module (4) is placed in a rectangular space surrounded by two adjacent excitation coils (33) and two rectangular iron cores (31), and the angle between two adjacent visualization imaging modules (4) is 90°.

7. The in-situ detection device for oil debris by visual imaging according to claim 1, characterized in that The device further includes a mounting seat (7). A lens screw sleeve (45) is provided on the visualization imaging module (4), and the visualization imaging module (4) is embedded into the internal space of the mounting seat (7) through the thread on the lens screw sleeve (45).

8. The in-situ detection device for oil debris by visual imaging according to claim 1, characterized in that The height of the oil cavity (6) is 0.5 mm to 5 mm.

9. The in-situ detection device for oil wear debris with visual imaging according to claim 1, characterized in that The air gap width between the N pole and the S pole of the magnet (34) is 0.5 mm to 5 mm.

10. An in-situ detection system for oil debris by visual imaging, characterized in that, It includes: a computer device (10) with a wireless communication function, a wireless network (11) communicating through Ethernet / 4G / 5G, a wireless communication module (12), a micro control unit (13), a pump (14), a solenoid valve (15), and a visualization imaging oil fluid wear debris in-situ detection device according to any one of claims 1 to 8. The computer device (10) sends a control instruction for instructing the in-situ detection of oil fluid wear debris. The control instruction is transmitted to the wireless communication module (12) through the wireless network (11), and the wireless communication module (12) converts the control instruction into a signal and then sends it to the micro control unit (13). The microcontroller unit (13) controls the pump (14) and the solenoid valve (15) to open, so that the oil flows through the inlet pipe joint (8) into the flow channel (1). After that, the flow guiding column (2) shunts the oil, enabling the oil to enter the oil cavity (6) to generate an oil circulation inside; controls each exciting coil (33) to be energized, so that a pulsating magnetic field is generated at the air gap between the N pole and the S pole of each pair of magnets (34), and the magnetic force of the pulsating magnetic field adsorbs the metal debris in the oil inside the oil cavity (6) on the inner surface of the light-transmitting toughened glass sheet (5), forming deposited debris at the air gap between the two magnetic poles of the magnet (34); controls the reflection light source (43) of the visualization imaging module (4) to illuminate the deposited debris adsorbed on the inner surface of the light-transmitting toughened glass sheet (5), so that the reflected light on the surface of the deposited debris is imaged on the photosensitive surface of the image device (42) through the optical lens (41), forming an image of the deposited debris; The visualization imaging module (4) is also used to transmit the obtained image of the deposited debris to the computer device (10) through the wireless communication module (12) and the wireless network (11), and the computer device (10) processes and analyzes the image of the deposited debris to complete the in-situ detection of oil debris.

Images